System and apparatus for axial field rotary energy device

ABSTRACT

An axial field rotary energy device can include a housing having an axis with an axial direction. A stator assembly can include stator panels that are discrete panels from each other. The stators panels can be mechanically and stationarily coupled to the housing. Each stator panel can include a printed circuit board (PCB) having coils that are electrically conductive, and each stator panel can operate with a single electrical phase. In addition, rotors can be rotatably mounted within the housing on opposite axial ends of the stator assembly. The rotors can be mechanically coupled together with a rotor spacer. Each rotor can include magnets. In addition, in one version, no rotor is disposed between axially adjacent ones of the stator panels.

This application is a continuation application of and claims priority toand benefit of U.S. application Ser. No. 16/212,884, filed on Dec. 7,2018, which is a continuation application of and claims priority to andbenefit of U.S. application Ser. No. 15/935,883, filed on Mar. 26, 2018,each of which is Incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION Field of the Disclosure

The present invention relates in general to an axial field rotary energydevice and, in particular, to a system, method and apparatus for modularmotors and generators having one or more printed circuit board (PCB)stators.

Description of the Prior Art

Conventional, axial air gap brushless motors with layered disk statorsare known, such as U.S. Pat. No. 5,789,841. That patent discloses astator winding that uses wires interconnected in a wave or lapconfiguration. Such motors are relatively large and difficult tomanufacture. Axial field electric devices that use PCB stators also areknown, such as U.S. Pat. Nos. 6,411,002, 7,109,625 and 8,823,241.However, some of these designs are complicated, relatively expensive andthey are not modular. Thus, improvements in cost-effective axial fieldrotary energy devices continue to be of interest.

SUMMARY

Embodiments of a system, method and apparatus for an axial field rotaryenergy device are disclosed. For example, an axial field rotary energydevice can include a housing having an axis with an axial direction. Astator assembly can include a plurality of stator panels that arediscrete panels from each other. The stator panels can be mechanicallyand stationarily coupled to the housing. Each stator panel can include aprinted circuit board (PCB) having coils that are electricallyconductive. Each stator panel can consist of a single electrical phase.In addition, rotors can be rotatably mounted within the housing onopposite axial ends of the stator assembly. The rotors can bemechanically coupled together with a rotor spacer. Each rotor caninclude magnets. In addition, in one version, no rotor is disposedbetween axially adjacent ones of the stator panels.

The foregoing and other objects and advantages of these embodiments willbe apparent to those of ordinary skill in the art in view of thefollowing detailed description, taken in conjunction with the appendedclaims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the features and advantages of theembodiments are attained and can be understood in more detail, a moreparticular description can be had by reference to the embodimentsthereof that are illustrated in the appended drawings. However, thedrawings illustrate only some embodiments and therefore are not to beconsidered limiting in scope as there can be other equally effectiveembodiments.

FIG. 1 is a top view of an embodiment of an axial field rotary energydevice.

FIG. 2 is a sectional side view of the device of FIG. 1, taken along theline 2-2 of FIG. 1.

FIG. 3 is an exploded isometric view of an embodiment of the device ofFIGS. 1 and 2.

FIG. 4 is a top view of an embodiment of a single phase stator having aprinted circuit board (PCB).

FIG. 5 is an enlarged isometric view of an embodiment of only the coillayers of a stator.

FIG. 6A is an enlarged, exploded, isometric view of another embodimentof only the coil layers of a stator.

FIG. 6B is an enlarged isometric view of a portion of the stator shownin FIG. 5.

FIG. 6C is an enlarged, exploded, isometric view of a portion of thestator shown in FIG. 5.

FIG. 6D is an enlarged isometric view of a portion of the stator shownin FIG. 5.

FIG. 7 is a schematic, partially exploded side view of an embodiment ofthe traces on the layers of a stator.

FIG. 8 is a top view of an embodiment of a multi-phase stator having aPCB.

FIG. 9 is a top view of an alternate embodiment of the top coil layer ofa stator and magnets of the vertically adjacent rotors.

FIG. 10 is a simplified top view of an embodiment of another embodimentof an axial field rotary energy device.

FIG. 11 is a simplified sectional side view of the device of FIG. 10.

FIG. 12 is a simplified, exploded, isometric view of an embodiment ofthe device of FIGS. 10 and 11.

FIG. 13 is a simplified top view of an embodiment of a segmented stator.

FIG. 14 is a simplified top view of another embodiment of a segmentedstator.

FIG. 15 is a simplified top view of an embodiment of traces for a PCB.

FIG. 16 is a simplified isometric view of the embodiment of FIG. 15.

FIG. 17 is a schematic, exploded, isometric view of an embodiment oftrace layers of the PCB of FIGS. 15 and 16.

FIG. 18 is a top view of an embodiment of a module.

FIG. 19 is a sectional side view of the module of FIG. 18, taken alongthe line 19-19 of FIG. 18.

FIG. 20A is an exploded isometric view of an embodiment of the module ofFIGS. 18 and 19.

FIGS. 20B-20H are isometric and sectional side views of embodiments ofthe module of FIG. 20A.

FIG. 21 is an exploded isometric view of another embodiment of a module.

FIG. 22 is an assembled isometric view of an embodiment of the module ofFIG. 21.

FIGS. 23 and 24 are isometric views of an embodiment of stacked moduleswith latches open and closed, respectively.

FIG. 25 is a top, interior view of an embodiment of a module.

FIG. 26 is an exploded isometric view of an embodiment of a body formodules.

FIG. 27 is a top view of an embodiment of a PCB stator for an axialfield rotary energy device.

FIG. 28 is an enlarged top view of a portion of an embodiment of the PCBstator of FIG. 27.

FIG. 29 is an isometric view of an embodiment of a stator that includesattached sensors.

FIG. 30 is an isometric view of an embodiment of a stator that includesembedded sensors.

FIG. 31 is an isometric view of an embodiment of an assembly for statorsegments.

FIG. 32 is an opposite isometric view of an embodiment of an assemblyfor stator segments.

FIG. 33 is an exploded isometric view of another embodiment of a device.

FIG. 34 is an axial sectional view of an embodiment of the device ofFIG. 33.

FIG. 35 is a top view of another embodiment of a stator panel.

FIG. 36 is a top, exploded view of still another embodiment of a statorpanel.

FIG. 37 is an enlarged, partial top view of yet another embodiment of astator panel.

FIG. 38 is an enlarged, partial top view of an alternate embodiment of astator panel.

The use of the same reference symbols in different drawings indicatessimilar or identical items.

DETAILED DESCRIPTION

FIGS. 1-3 depict various views of an embodiment of a device 31comprising an axial field rotary energy device (AFRED). Depending on theapplication, device 31 can comprise a motor that converts electricalenergy to mechanical power, or a generator that converts mechanicalpower to electrical energy.

I. Panels

Embodiments of device 31 can include at least one rotor 33 comprising anaxis 35 of rotation and a magnet (i.e., at least one magnet 37). Aplurality of magnets 37 are shown in the embodiment of FIG. 3. Eachmagnet 37 can include at least one magnet pole. The magnets 37 cancomprise various shapes, such as trapezoidal, conical, etc.

Device 31 also can include a stator 41 that is coaxial with the rotor33. Rotor 33 can be coupled on a shaft 43 and with other hardware, suchas one or more of the following items: a mount plate, fastener, washer,bearing, spacer or alignment element. Embodiments of the stator 41 caninclude a single unitary panel, such as the printed circuit board (PCB)45 shown in FIG. 4. PCB 45 can include at least one PCB layer 47. Forexample, certain embodiments described herein include twelve PCB layers47. PCB layers 47 can be parallel and spaced apart in the axialdirection. Each PCB layer 47 can include at least one conductive trace49. Each trace 49 is a separate conductive feature formed on a given PCBlayer 47. For example, eight traces 49 are shown in FIG. 4. Traces 49can be configured in a desired pattern, such as the coils Illustrated inFIG. 4.

FIG. 4 depicts an embodiment of one PCB layer 47 within a twelve-layerPCB 45. The other eleven PCB layers are similar, with differencesdescribed below in regards to subsequent figures. On the Illustrated PCBlayer 47, each trace 49 (forming a single coil) includes a firstterminal 51 at the outer edge of the coil, and a second terminal 53 inthe center of coil. Traces 49 are connected to other traces 49 usingvias 55. A first set of vias 55 is disposed adjacent to the firstterminal 51 at the outer edge of each coil, and a second set of vias 55is disposed adjacent to the second terminal in the center of each coil.In this embodiment, traces 49 on the illustrated PCB layer 47 are notdirectly connected to an adjacent trace 49 on this illustrated PCB layer47, but rather are each directly connected to a corresponding trace 49on another PCB layer 47, as more thoroughly explained in regards to FIG.5 and FIGS. 6A-6D.

In this embodiment, each trace 49 is continuous and uninterrupted fromits first terminal 51 to its second terminal 53, and connections to suchtrace 49 are made only to the first and second terminals 51, 53. Eachtrace 49 includes no other terminals for electrical connections. Inother words, each trace 49 can be seamlessly continuous with no otherelectrical connections, including no additional vias 55, between thefirst and second terminals 51, 53. Also shown in FIG. 4, the width of agiven trace 49 can be not uniform. For example width 171 correspondingto an outer trace corner can be wider than width 173 corresponding to aninner trace corner. Gap 175 between adjacent concentric trace portionsforming a single coil can be the same or different than the gap 177between adjacent traces (i.e., separate coils). In some embodiments, agiven trace can comprise an outer width that is adjacent an outerdiameter of the PCB and in a plane that Is perpendicular to the axis 35,and an inner width that is adjacent an inner diameter of the PCB and inthe plane. In some embodiments the outer width can be greater than theinner width. In some embodiments a given trace can comprise inner andouter opposing edges that are not parallel to each other.

FIG. 5 depicts an embodiment of a twelve-layer PCB 45 incorporating thePCB layer 47 shown in FIG. 4. Each of the twelve PCB layers 47 areclosely spaced and form a “sandwich” of PCB layers 47, labeled as47.1-12. On the uppermost PCB layer 47.1, a first trace 49.11 (alsodescribed herein as “coil 49.11”) is shown whose first terminal 51.1 iscoupled to an external terminal 61 for the device 31. On the lowermostPCB layer 47.12, a trace 49.128 is shown whose first terminal 51.12 iscoupled to an external terminal 63 for the device 31. In thisembodiment, there are eight traces 49 (coils) on each of twelve PCBlayers 47.1-12. These traces are coupled together (as more fullydescribed below) such that current flowing into the external terminal 61will flow through the ninety-six coils, then flow out the externalterminal 63 (or conversely flow into external terminal 63 and outexternal terminal 61). In this embodiment, only one trace 49 (e.g., coil49.11) is coupled to the external terminal 61 for the device 31, andonly one trace 49 (e.g., coil 49.128) is coupled to the externalterminal 63 for the device 31. For a motor, both external terminals 61,63 are input terminals and, for a generator, both external terminals 61,63 are output terminals. As can be appreciated in this embodiment, eachPCB layer includes a plurality of coils that are co-planar and angularlyand symmetrically spaced apart from each other about the axis, and thecoils in adjacent PCB layers, relative to the axis, arecircumferentially aligned with each other relative to the axis to definesymmetric stacks of coils in the axial direction.

FIG. 6A is an exploded view of a portion of the twelve-layer PCB 45shown in FIG. 5, which is labeled to better illustrate how the coils arecoupled together by vias 55, 59, and thus to better illustrate howcurrent flows into the external terminal 61, through the ninety-sixcoils, then flows out the external terminal 63. Assume that inputcurrent 81.1 flows into external terminal 61. This current flows“spirally” around coil 49.11 (on PCB layer 47.1) as current 81.2 and81.3, and reaches the second terminal 53 of coil 49.11. A via 55.1couples the second terminal 53 of coil 49.11 to the second terminal ofthe corresponding coil 49.21 on PCB layer 47.2 directly below coil49.11. Thus, the current flows through via 55.1 as current 81.4, thenflows spirally around coil 49.21 as current 81.5 until it reaches thefirst terminal 51 for coil 49.21. A via 55.2 couples the first terminal51 of coil 49.21 to the first terminal of coil 49.12 on PCB layer 47.1,which is adjacent to the first coil 49.11. In this embodiment, thetraces 49 on the first PCB layer 47.1 are generally reversed(mirror-imaged) relative to those on the second PCB layer 47.2, so thatthe via 55.1 overlaps with both “tabs” on the respective second terminal53 of coils 49.11 and 49.21, and likewise so that the via 55.2 overlapswith both “tabs” on the respective first terminal 51 of coils 49.12 and49.21, as is more thoroughly described below in regards to subsequentfigures. Thus, the current flows through via 55.2 as current 82.1 to thefirst terminal 51 of coil 49.12 on PCB layer 47.1.

From this terminal, the current flows through coils 49.12 and 49.22similarly to that described for coils 49.11 and 49.21. For example, thecurrent flows around coil 49.21 (on PCB layer 47.1) as current 82.2 and82.3 to the second terminal 53 of coil 49.21, flows through via 55.3 ascurrent 82.4 to the second terminal 53 of coil 49.22, then flows ascurrent 82.5 and 82.6 around coil 49.22 until it reaches the firstterminal 51 for coil 49.22. As before, a via 55.4 couples the firstterminal 51 of coil 49.22 to the first terminal 51 of coil 49.13 on PCBlayer 47.1, which is adjacent to coil 49.12. This coupling configurationis replicated for all remaining traces 49 on the upper two PCB layers47.1, 47.2, and the current flows through these remaining traces 49until it reaches the last coil 49.28 on PCB layer 47.2. The current,after having already flowed through all sixteen coils on the upper twoPCB layers 47.1, 47.2, is now directed to the next PCB layer 47.3.Specifically, a via 59.1 couples the first terminal 51 of coil 49.28 tothe first terminal of coil 49.31 on PCB layer 47.3, which is directlybelow coils 49.11 and 49.21. In this embodiment there is only one suchvia 59 coupling a coil on PCB layer 47.2 to a coil on PCB layer 47.3.Conversely, there are fifteen such vias 55 coupling together coils onPCB layers 47.1, 47.2. In this embodiment such coupling occurs only atthe first and second terminals 51, 53 of the coils.

The vias 55 between the third and fourth PCB layers 47.3, 47.4 areconfigured identically as those between the first and second PCB layers47.1, 47.2 described above, and thus the via configuration and thecorresponding current flow need not be repeated. This continues downwardthrough the PCB layer “sandwich” until reaching the lowermost PCB layer47.12 (not shown here). As described above, the first terminal 51 fortrace (coil) 49.128 is coupled to the external terminal 63.Consequently, the current that flows inward through external terminal61, after flowing through all ninety-six coils, flows outward throughexternal terminal 63.

FIG. 6B is an enlarged view of a group of vas 55 shown in FIG. 5. Thisvia group is adjacent to the respective second terminal 53 for each of agroup of vertically aligned coils 49.1-12 on each of the twelve PCBlayers 47.1-12. As noted above, the traces 49 on the second PCB layer47.2 are generally reversed (mirror-imaged) relative to those on thefirst PCB layer 47.1, so that the via 55 overlaps with both “tabs” onthe respective second terminal 53 of these vertically adjacent coils. Asshown in FIG. 6B, on coil 49.18 (first layer, eighth coil) the secondterminal 53.18 includes a tab extending to the side of the trace. Inmirror-image fashion, on coil 49.28 (second layer, eighth coil) thesecond terminal 53.28 includes a tab extending in the opposite directionto the side of the trace, so that these two tabs overlap. A via 55couples together these two overlapping tabs. In like manner, since theembodiment shown includes 12 PCB layers 47, each of five additional vias55 respectively couples overlapping terminals 53.38 and 53.48,overlapping terminals 53.58 and 53.68, overlapping terminals 53.78 and53.88, overlapping terminals 53.98 and 53.108, and overlapping terminals53.118 and 53.128.

FIG. 6C shows two of these vias 55 in an exploded format. Terminal 53.38of coil 49.38 overlaps with terminal 53.48 of coil 49.48, and arecoupled together by a first via 55. Terminal 53.58 of coil 49.58overlaps with terminal 53.68 of coil 49.68, and are coupled together bya second via 55. As can be clearly appreciated in the figures, thesepairs of overlapping tabs, together with their corresponding vias 55,are staggered in a radial direction so that such vias 55 can beimplemented using plated through-hole vias. Alternatively, such vias 55can be implemented as buried vias, in which case the vias need not bestaggered, but rather can be vertically aligned.

FIG. 6D is an enlarged view of a group of vias 59 also shown in FIG. 5.In this embodiment, these vias 59 are disposed in the gap between onespecific adjacent pair of vertically aligned coils 49 (e.g., betweenuppermost layer coil 49.11 and 49.18), whereas vias 55 are disposed inthe other gaps between other adjacent pairs of vertically aligned coils49. In this figure, the vias 59 are shown as plated through-hole vias.Vias 55, 59 overlap with both “tabs” on the respective first terminal 51of the corresponding coils. Vias 55 couple horizontally adjacent coilson vertically adjacent layers, while vias 59 couple horizontally alignedcoils on vertically adjacent layers, both as shown in FIG. 6A. There areonly five vias 59 shown in this embodiment because the first terminal 51on the uppermost coil 49.11 is coupled to the external terminal 61, andthe first terminal 51 of coil 49.128 on the lowermost PCB layer 47.12 iscoupled to the external terminal 63, leaving only 10 PCB layers(47.2-11) having coils whose respective first terminals 51 are coupledtogether in pairs. For example, the innermost via 59.5 couples arespective coil on PCB layer 47.10 to a respective coil on PCB layer47.11.

In various embodiments, each trace 49 can be electrically coupled toanother trace 49 with at least one via 55. In the example of FIG. 6A,each PCB layer 47 has eight traces 49 and only one via 55 between traces49. In some embodiments, every trace 49 is electrically coupled toanother trace 49. Together, two traces 49 define a trace pair 57. InFIG. 7, there are twelve PCB layers 47.1-12, and there are six tracepairs 57.1-6.

Each trace pair 57 can be electrically coupled to another trace pair 57with at least one other via 59 (e.g., such as only one via 59). In someversions, the traces 49 (e.g., coils) in each trace pair 57 (e.g., coilpair) can be located on different PCB layers 47, as shown in FIG. 6A. Inother versions, however, the traces 49 in each trace pair 57 can beco-planar and located on the same PCB layer 47.

In some embodiments, at least two of the traces 49 (e.g., coils) areelectrically coupled in series. In other versions, at least two of thetraces 49 (e.g., coils) are electrically coupled in parallel. In stillother versions, at least two of the traces 49 are electrically coupledin parallel, and at least two other traces 49 are electrically coupledin series.

Embodiments of the device 31 can include at least two of the trace pairs57 electrically coupled in parallel. In other versions, at least two ofthe trace pairs 57 are electrically coupled in series. In still otherversions, at least two of the trace pairs 57 are electrically coupled inparallel, and at least two other trace pairs 57 are electrically coupledin series.

As depicted in FIGS. 4 and 6, each PCB layer 47 (only the top PCB layer47 is shown in the top views) comprises a PCB layer surface area (LSA)that is the total surface area (TSA) of the entire (top) surface of thePCB 45. The TSA does not include the holes in the PCB 45, such as thecenter hole and the mounting holes that are illustrated. The one or moretraces 49 (eight coils shown in FIG. 4) on the PCB layer 47 can comprisea coils surface area (CSA). The CSA includes the entire footprints ofthe coils (i.e., within their perimeters), not just their “coppersurface area”. The CSA can be in a range of at least about 50% of thePCB layer surface area, such as at least about 55%, at least about 60%,at least about 65%, at least about 70%, at least about 75%, at leastabout 80%, at least about 85%, at least about 90%, at least about 95%,at least about 97%, or even at least about 99% of the PCB layer surfacearea. In other embodiments, the coils surface area can be not greaterthan 99% of the PCB layer surface area, such as not greater than about95%, not greater than about 90%, not greater than about 85%, not greaterthan about 80%, not greater than about 75%, or even not greater thanabout 70% of the PCB layer surface area. In other embodiments, the coilssurface area can be in a range between any of these values.

The CSA also can be calculated with respect to any sensors or circuitry(such as IOT elements) on or in the PCB. The IOT elements can be limitedto not greater than 50% of the TSA. Additionally, the IOT elements canbe embedded within the CSA or embedded in at least part of the TSA thisis not included in the CSA.

The total area of each trace that forms a coil (i.e., including theconductive traces, but cannot necessarily include the spaces between theconductive traces) can be viewed as a coil surface area. It is believedthat performance of the device 31 is improved with increasing aggregatecoil surface area, relative to the underlying PCB layer surface area onwhich the coil(s) is formed.

In some embodiments (FIG. 4), the device 31 can comprise a stator 41comprising a single electrical phase. Versions of the stator 41 canconsist of a single electrical phase. Each PCB layer 47 can comprise aplurality of coils that are co-planar and symmetrically spaced apartabout the axis 35 (FIGS. 2 and 3). In one example, each coil consists ofa single electrical phase.

FIG. 8 depicts an embodiment of the stator 41 comprising at least twoelectrical phases (e.g., three phases shown). Each PCB layer 47 caninclude a plurality of coils (such as traces 49) as shown for eachelectrical phase. For example, FIG. 8 illustrates coils corresponding tothree phases A, B and C. The coils for each electrical phase A, B, C canbe angularly offset from each other with respect to the axis 35 (FIGS. 2and 3) within each PCB layer 47 to define a desired phase angle shiftbetween the electrical phases A, B, C. In FIG. 6, there are nine traces49 on each PCB layer 47. Since the embodiment of stator 41 in FIG. 8 isthree phases, each trace 49 in phase A is 120 electrical degrees apartfrom other traces 49 for phase A, and 40 electrical degrees apart fromadjacent traces 49 for phases B and C. The traces 49 for phase B(relative to phases A and C) and for phase C (relative top phases A andB) are spaced likewise.

In some embodiments, each coil (e.g., trace 49) can consist of a singleelectrical phase. Alternatively, the coils can be configured to enablethe stator 41 with two or more electrical phases (e.g., three phasesshown in FIG. 8).

The example in FIG. 9 is a simplified view of only some interiorcomponents of an embodiment of device 31. Each of the magnets 37 caninclude a magnet radial edge or element 67 (also referred to herein as a“magnet radial edge 67”), and each of the traces 49 can include a traceradial edge or element 69 (also referred to herein as a “coil radialedge 69”). The magnets 37 are part of the rotor 33 (FIG. 2) and rotateabout the axis 35 with respect to the stationary stator 41. When radialedge portions of the magnets 37 and the traces 49 rotationally alignrelative to the axis during operation of the device 31, at leastportions of the radial elements 67, 69 can be skewed (i.e., notparallel) relative to each other. In some embodiments, when radial edgeportions of the magnets and coils rotationally align relative to theaxis, the magnet radial edges and coil radial edges are not parallel andare angularly skewed relative to each other. FIG. 9 illustrates arotation position of the magnets 37 for which a radial edge portion ofthe magnet 37 (i.e., the magnet radial edge 69 nearing the corner of themagnet 37) is rotationally aligned with a radial edge portion of thecoil 49, and which illustrates the skew between the magnet radial edge69 and the coil radial edge 67. In one version, the radial elements 67,69 can be leading radial edges or trailing radial edges of the magnets37 and traces 49. In another example, the magnet and trace radial edgesor elements 67, 69 can be linear as shown, and no portions of the magnetand trace radial elements 67, 69 are parallel when the magnets 37 andtraces 49 rotationally align in the axial direction.

In some embodiments, the magnet radial elements 67 can be angularlyskewed relative to the trace radial elements 69, and the angular skewcan be greater than 0 degrees, such as greater than 0.1 degrees, atleast about 1 degree, at least about 2 degrees, at least about 3degrees, at least about 4 degrees, or even at least about 5 degrees. Inother versions, the angular skew can be not greater than about 90degrees, such as not greater than about 60 degrees, not greater thanabout 45 degrees, not greater than about 30 degrees, not greater thanabout 25 degrees, not greater than about 15 degrees, not greater thanabout 10 degrees, or even not greater than about 5 degrees.Alternatively, the angular skew can be in a range between any of thesevalues.

In an alternate embodiment, at least portions of the radial elements 67,69 can be parallel to each other during rotational alignment.

II. Segments

Some embodiments of an axial field rotary energy device can beconfigured in a manner similar to that described for device 31,including assembly hardware, except that the stator can be configuredsomewhat differently. For example, FIGS. 10-12 depict a simplifiedversion of a device 131 with only some elements shown for ease ofunderstanding. Device 131 can include a stator 141 that is coaxial witha rotor 133. Optionally, each rotor 133 can include one or more slits orslots 136 (FIG. 10) that extend therethrough. In some versions, theslots 136 are angled with respect to axis 135 (FIG. 12) and, thus, arenot merely vertical. The angles of the slots 136 can be provided atconstant slopes, and can facilitate a cooling air flow within the device131. Slots 136 can enable air flow to be pulled or pushed through and/oraround the rotors 133 and effectively cool the stators 141. Additionalslots can be provided in rotor spacers, such as rotor spacer 143 (FIG.12), particularly in embodiments having a plurality of stator segments,and particularly in embodiments having an inner diameter R-INT of thestator assembly (FIG. 14) irrespective of the outer diameter R-EXT.

Rather than comprising a single panel PCB 45 as described for stator 41,the stator 141 can include a plurality of stator segments 142, each ofwhich can be a separate PCB 145. The stator segments 142 can be coupledtogether, such as mechanically and electrically coupled together. Eachstator segment 142 can include a printed circuit board (PCB) having oneor more PCB layers 147 (FIG. 13) as described elsewhere herein. In oneexample, each PCB 145 can have an even number of PCB layers 147. In analternate embodiment, the PCB 145 can have an odd number of PCB layers147.

Embodiments of the stator segments 142 can comprise or correspond toonly one electrical phase. Moreover, the stator 141 of device 131 canconsist of or correspond to only one electrical phase. In otherversions, the stator 141 can comprise or correspond to a plurality ofelectrical phases. As shown in FIG. 13, each stator segment 142 includesat least one PCB layer 147 having at least one conductive trace 149,such as the coil illustrated. In some versions (FIG. 14), each statorsegment 142 can have at least one PCB layer 147 having a plurality oftraces 149 (e.g., coils) that are co-planar and angularly spaced apartfrom each other relative to the axis 135 (FIGS. 11 and 12). In oneexample, each trace 149 can comprise a single electrical phase. Inanother version, each stator segment 142 can include a plurality of PCBlayers 147, each of which can be configured to correspond to only oneelectrical phase. In some versions, each PCB layer 147 on each statorsegment 142 can include a plurality of axially co-planar traces 149 thatare configured to correspond to only one electrical phase.

In some embodiments (FIG. 13), each PCB layer 147 can include at leastone radial trace 150 that extends from about an inner diameter (ID) ofthe PCB 145 to about an outer diameter (OD) of the PCB 145. In oneexample, each PCB layer 147 can include a trace 149 that is continuousfrom an outermost trace portion 152 to a concentric innermost traceportion 154. The traces 149 can include radial traces 150 having linearsides and chamfered corners 156. The linear sides of the radial tracescan be tapered, having an increasing trace width with increasing radialdistance. Inner end turn traces 146 and outer end turn traces 148 extendbetween the radial traces 150 to form a concentric coil.

Regarding the tapered traces and coils, the tapers can improve theamount of conductive material (e.g., copper) that can be included in aPCB stator. Since many motors and generators comprise a round shape, thecoils can be generally circular and, to fit together collectively on astator, the perimeters of the coils can be somewhat pie-slice-shaped ortriangular. In some versions, the coils can have a same width in a planeperpendicular to the axis, and in other versions the coils can betapered to increase the conductor (e.g., copper) densities of the coils.Improving copper density can have significant value to reduce electricalresistance, I.sup.2R losses and heat generation, and increase theability to carry a higher electrical current to provide a machine withhigher efficiency.

In another version, each PCB layer 147 can include only linear traces149 (FIGS. 15-17). Linear traces 149 can be continuous from an outermosttrace 152 to a concentric innermost trace 154. In one example, no trace149 of the PCB layers 147 is non-linear. However, embodiments of theonly linear traces 149 can include turns, such as, for example, roundedcorners or chamfered corners. As used herein, a “turn” includes a traceportion connecting a radial trace to an end turn trace. In otherembodiments, the PCB layer 147 can include one or more non-linear, suchas curvilinear traces.

As noted herein, the PCB 145 can include a plurality of PCB layers 147that are spaced apart from each other in the axial direction. The PCBlayers 147 can comprise layer pairs 157 (FIG. 17; see pairs 157.1 to157.4). Each layer pair 157 can be defined as two PCB layers that areelectrically coupled together. In one version, at least one of the PCBlayers 147 is electrically coupled to another PCB layer 147 in series orin parallel. In another version, at least one layer pair 157 iselectrically coupled to another layer pair 157 in series or in parallel.In one embodiment, at least one of the layer pairs 157 comprises two PCBlayers 147.6 and 147.7 that are axially adjacent to each other. Inanother embodiment, at least one of the layer pairs 157 comprises twoPCB layers 147.1 and 147.3 that are not axially adjacent to each other.Similarly, at least one of the layer pairs 157 can be axially adjacentto the layer pair 157 to which said at least one of the layer pairs iselectrically coupled. Conversely, at least one of the layer pairs 157can be not axially adjacent to the layer pair 157 to which said at leastone of the layer pairs 157 is electrically coupled.

Embodiments of the PCB layers 147 can include at least one layer set 181(FIG. 17). For example, layer set 181 can include a first layer 147.1, asecond layer 147.2, a third layer 147.3 and a fourth layer 147.4. Insome versions, a first via 159 can couple the first layer 147.1 to thethird layer 147.3, a second via 155 can couple the third layer 147.3 tothe second layer 147.2, and a third via 159 can couple the second layer147.2 to the fourth layer 147.4. In one example, the first, second andthird vias 159, 155, 159 are the only vias that intra-couple the layerset 181. In these examples, the two, directly axially adjacent PCBlayers 147.1 and 147.2 are not directly electrically coupled to eachother. In FIG. 17 each of the vias 159 couples a pair of non-adjacentPCB layers 147 while bypassing (i.e., making no contact to) theintervening PCB layer 147. For example, via 159.1 couples PCB layer147.1 to PCB layer 147.3, and makes no contact with PCB layer 147.2.Conversely, each of the vias 155 couples a pair of adjacent PCB layers147. For example, via 155.2 couples PCB layer 147.2 to PCB layer 147.3.Each via 155, 159 that couples together a respective pair of PCB layers,forms a corresponding layer pair 157. For example, layer pair 157.1includes PCB layer 147.1 and PCB layer 147.3. Layer pair 157.2 includesPCB layer 147.2 and PCB layer 147.3. Layer pair 157.3 includes PCB layer147.2 and PCB layer 147.4. Layer pair 157.4 includes PCB layer 147.4 andPCB layer 147.5. Layer pair 157.5 includes PCB layer 147.5 and PCB layer147.7. Layer pair 157.6 includes PCB layer 147.6 and PCB layer 147.7.Layer pair 157.7 includes PCB layer 147.6 and PCB layer 147.8.

In FIG. 17, each via is shown having a blunt end and a pointed end. Thisshape is not intended to imply any structural difference between the twoends of each via, but rather is intended to provide a consistentindication of the direction of current flow through each via. Moreover,while each via is also shown as extending vertically only as far asnecessary to couple the corresponding pair of PCB layers 147, in certainembodiments each via can be implemented as a plated through-hole viaextending through the entire PCB (e.g., see vias 59 in FIG. 60D). Eachof such plated through-hole vias can make contact with any PCB layer 147having a trace 149 that overlaps such a via. In the embodiment shown inFIG. 17, a given through-hole via overlaps and makes a connection withonly two PCB layers 147, while the traces 149 of all remaining PCBlayers 147 do not overlap the given via and are not connected to thegiven via.

Alternatively, some embodiments can include buried vias that verticallyextend only between the corresponding PCB layers 147 to be connected.

III. Modules

FIGS. 18, 19, 20A-20H disclose embodiments of a module 201 for one ormore axial field rotary energy devices 231. Device(s) 231 can compriseany of the axial field rotary energy device embodiments disclosedherein. In the embodiments shown in these figures, the module 201includes a housing 203 having a side wall 211, three stators (shown asPCB stator panel 245), and four rotor assemblies 242, 244. Each rotorassembly 244 is vertically disposed between two stators 245, andincludes a pair of identical rotor panels 236 and a group of rotorpermanent magnets 237. Each rotor panel 236 includes a set of recessedindentations to position each of the rotor magnets 237, and the tworotor panels 236 are secured together to sandwich each of the group ofrotor magnets between the opposing upper and lower rotor panels 236.Each rotor assembly 242 is vertically disposed between a stator 245 anda housing 203, and includes a torque plate 233, a rotor panel 234, and agroup of rotor permanent magnets 237.

The vertical spacing between rotor assemblies (e.g., 242, 244) ismaintained by spacers (e.g., 262, 263) that extend from one rotorassembly to the adjacent rotor assembly through a hole in theintervening stator panel 245. The rotor spacing corresponds to thethickness of the stator panel 245 and the desired air gap spacing (suchas above and/or below) the stator panel 245. Each rotor spacer candefine the air gap between the rotor assembly and the stator (and alsocan define the height 215 of the side wall slots, as noted below). Eachrotor spacer is positioned between two rotor assemblies. For example,rotor spacer 262 is positioned between the uppermost rotor assembly 242and the adjacent inner rotor assembly 244 (and likewise for thelowermost rotor assembly 242). Each rotor spacer 263 is positionedbetween adjacent inner rotor assemblies 244. As is depicted here, suchrotor spacer 263 can have a different thickness as rotor spacer 262, dueto mechanical differences in the uppermost and lowermost rotorassemblies 242 relative to the inner rotor assemblies 244, to define thesame air gap spacing between all rotors and stators. The use of therotor spacers 262, 263 enables stacking multiple rotors (e.g., rotorassemblies 242, 244), which can provide significant flexibility in theconfiguration of module 201.

Embodiments of the housing 203 can include a side wall 211 (FIGS.20A-20H and 21). Side wall 211 can be configured to orient the stator(e.g., stator panel 245) at a desired angular orientation with respectto the axis 235. For applications including a plurality of stators 245,the side wall 211 can comprise a plurality of side wall segments 212.The side wall segments 212 can be configured to angularly offset theplurality of stators 245 at desired electric phase angles (see, e.g.,FIGS. 20C and 25) for the module 201, relative to the axis. In oneexample, the side wall 211 can include a radial inner surface having oneor more slots 214 formed therein. Each slot 214 can be configured toreceive and hold the outer edge of the stator 245 to maintain thedesired angular orientation of the stator 245 with respect to the axis235. In the embodiment shown in FIGS. 20A-20H, each side wall 211includes three slots 214 formed between mating pairs of side wallsegments 212. In some embodiments the upper and lower sidewall segments212 of such mating pair are identical and thus can be usedinterchangeably, but in other contemplated embodiments the upper andlower side wall segments 212 can be different due to asymmetrical slots214, differences in mounting hole placement, or some other aspect.

In addition to providing the angular offset of the stators 245 asdescribed above, the slots 214 can be configured to axially, such asvertically, position the outer edge of each stator 245 at prescribedaxial positions with respect to other stators 41. Since the rotorspacers 262, 263 determine the axial spacing between each stator 245 (atthe innermost extent thereof) and the corresponding rotor assembly(e.g., 242, 244 in FIGS. 20A, 20B, and 20D) on either axial side (e.g.,above and below) each stator 245, the combination of the side wall slots214 (i.e., the height 215 of such slots 214) and the rotor spacers 262,263 serve to maintain a precise air gap spacing between stators 245 androtor assemblies 242, 244. In other embodiments having a single stator245, each side wall segment 212 can be configured to provide one sidewall slot 214. The group of side wall segments 212 together providenumerous slots 214 (e.g., eight such slots 214) radially spaced aroundthe module 201. Collectively such side wall slots 214 can be viewed asfacilitating the air gap spacing between the stator and the adjacentrotor.

Versions of the module 201 can include a housing 203 having mechanicalfeatures (e.g., keyed shafts 209 in FIG. 21) configured to mechanicallycouple the housing 203 to a second housing 203 of a second module 201.In addition, housing 203 can be configured with electrical elements(e.g., electrical connector couplings 204 in FIGS. 21 and 22) toelectrically couple the housing 203 to the second housing 203. In oneexample, the module 201 is air cooled and is not liquid cooled. In otherversions, liquid-cooled embodiments can be employed.

In some examples, the module 201 can be configured to be indirectlycoupled to the second module 201 with an intervening structure, such asa frame 205 (FIGS. 21-22). The module 201 can be configured to bedirectly coupled to the frame 205, such that the module 201 isconfigured to be indirectly coupled to the second module 201 with othercomponents depending on the application. In another example, the module201 can be configured to be directly coupled to the second module 201without a frame, chassis or other intervening structure.

In some embodiments, at least one rotor 233, at least one magnet 237 andat least one stator 241 having at least one PCB 245 with at least onePCB layer 147 having at least one trace 149, can be located inside andsurrounded by the housing 203.

In some versions, each module 201 consists of a single electrical phase.In other versions each module 201 comprises a plurality of electricalphases. Examples of each module 201 can include a plurality of PCBpanels 245 (FIGS. 20A-20H). Each PCB panel 245 can comprise a singleelectrical phase or a plurality of electrical phases. The PCB panels canbe unitary panels or can comprise stator segments as described elsewhereherein.

In one version, the module 201 and the second module 201 can beconfigured to be identical to each other. In another version, the module201 and the second module 201 can differ. For example, the module 201can differ from the second module 201 by at least one of the followingvariables: power input or output, number of rotors 233, number ofmagnets 237, number of stators 41 (see previous drawings), number ofPCBs 245, number of PCB layers 47 (see previous drawings), number oftraces 49 (see previous drawings), and angular orientation with respectto the axis 235. For example, in some embodiments one or more of thesevariables can be modified to achieve differences in power efficiency,torque, achievable revolutions per minute (RPM), so that differentmodules 201 can be utilized to better tailor operation as a function ofthe load or other desired operating parameter.

Some embodiments of the module 201 can include at least one latch 207(FIGS. 23 and 24) configured to mechanically secure the modulestogether. FIG. 23 depicts modules nested together with the latches 207open, and FIG. 24 depicts modules nested together with the latches 207closed. In one example, the latches 207 can be symmetrically arrayedwith respect to the axis 235. In another version, a top module (notshown) can be configured to be axially on top of another module, and thetop module can differ structurally from the second module. For example,the top module 201 can include latches 207 only on its bottom side, andomit such latches 207 on its top side. As another example, the shaft 209can extend from the bottom module 201, but not from the top module 201.

As shown in FIGS. 21-24, the module 201 can include a keyed shaft 209.Module 201 can be mounted to the keyed shaft which can be configured tomechanically couple to another module 201.

Some embodiments can further comprise a body 213 (FIG. 26) (alsoreferred to herein as an “enclosure”). Body 213 can be configured tocontain and coaxially mount a plurality of the modules 201 within thebody 213. In the example illustrated, the body 213 comprises two halvesthat are coupled together with fasteners. For versions where each module201 comprises a single electrical phase, and the body 213 can beconfigured to maintain the modules 201 at a desired electrical phaseangle with respect to the axis 235. For versions where the body 213comprises a plurality of electrical phases, and the body 213 can beconfigured to maintain the modules 201 at desired electrical phaseangles with respect to the axis 235.

In other versions, there can be a plurality of bodies 213. Each body 213can include mechanical features such as coupling structures configuredto mechanically couple each body 213 to at least one other body 213, andelectrical elements configured to electrically couple each body 213 toat least one other body 213. Each body 213 can be configured to directlyor indirectly couple to at least one other body 213.

In some generator embodiments, a body (or more than one intercoupledbodies) can include a number of electrical phases (such as about 4 to99; e.g., at least 10, 11, 12, 13, 14, 15 or more) electrical phases ofalternating current output. Thus, the AC current output can act like aDC-like output ripple without being rectified or requiring a powerconversion. In other versions, such AC current output can be rectified.

Embodiments of a system for providing energy also are disclosed. Forexample, the system can include a plurality of modules 201 comprisingaxial field rotary energy devices. The modules 201 can beinterchangeably connectable to each other to configure the system for adesired power output. Each module can be configured based on any of theembodiments described herein. The system can comprise a generator or amotor. Embodiments of the system can include at least two of the modules201 configured to differ. For example, the modules 201 can differ fromeach other by at least one of the following variables: power output orinput, number of rotors, number of magnets, number of stators, number ofPCBs, number of PCB layers, number of coils, and angular orientationwith respect to the axis.

Embodiments of a method of repairing an axial field rotary energy deviceare disclosed as well. For example, the method can include the followingsteps: providing a body 213 having a plurality of modules 201. Eachmodule 201 can be configured as described for any of the embodimentsdisclosed herein. The method also can include mechanically andelectrically coupling the modules 201 such that the modules 201 arecoaxial; operating the axial field energy device; detecting a problemwith one of the modules 201 and stopping operation of the axial fieldenergy device; opening the body 213 and de-attaching the problem module201 from all other modules 201 to which the problem module 201 isattached; installing a replacement module 201 in the body 213 in placeof the problem module 201 and attaching the replacement module 201 tothe other modules 201 to which the problem module 201 was attached; andthen re-operating the axial field energy device.

Other embodiments of the method include angularly aligning the modulesto at least one desired electrical phase angle with respect to the axis.In another version, the method can include providing a plurality ofbodies 213, and mechanically and electrically coupling the bodies 213.

Still other embodiments of a method of operating an axial field rotaryenergy device can include providing an enclosure having a plurality ofmodules, each module comprises a housing, rotors rotatably mounted tothe housing, each rotor comprises an axis and a magnet, stators mountedto the housing coaxially with the rotors, each stator comprises aprinted circuit board (PCB) having a coil, each stator consists of asingle electrical phase, and selected ones of the stators are set atdesired phase angles with respect to the axis; mechanically andelectrically coupling the modules such that the modules are coaxialwithin the enclosure; and then operating the axial field energy device.In other words, setting the single phase stators at the same phase anglecan form a single phase machine, and setting the single phase stators atvarying phase angles can form a multi-phase machine (or more than 2phases).

Optionally, the enclosure and each module can comprise a singleelectrical phase, and the method can comprise angularly aligning themodules at a desired electrical phase angle with respect to the axis.The method can include the enclosure with a plurality of electricalphases, each module comprises a single electrical phase, and angularlyorienting the modules at desired electrical phase angles with respect tothe axis. The enclosure and each module can include a plurality ofelectrical phases, and angularly misaligning the modules at desiredelectrical phase angles with respect to the axis.

Some versions of the method can include providing a plurality of bodies,and the method further comprises mechanically and electrically couplingthe bodies to form an integrated system. Each module can include aplurality of stators that are angularly offset from each other withrespect to the axis at desired electrical phase angles. In one example,each stator consists of only one PCB. In other examples, each statorcomprises two or more PCBs that are coupled together to form eachstator. In still another version, the enclosure can have a numberelectrical phases of alternating current (AC) output that issubstantially equivalent to a clean direct current (DC)-like ripplewithout a power conversion, as described herein.

In other versions, a method of repairing an axial field rotary energydevice can include providing a plurality of bodies that are coupledtogether, each enclosure having a plurality of modules, each modulecomprising a housing, a rotor rotatably mounted to the housing, therotor comprises an axis and a magnet, a stator mounted to the housingcoaxially with the rotor, and the stator comprises a printed circuitboard (PCB); mechanically and electrically coupling the modules;operating the axial field rotary energy device; detecting an issue witha first module in a first enclosure and stopping operation of the axialfield rotary energy device; opening the first enclosure anddisassembling the first module from the first enclosure and any othermodule to which the first module is attached; installing a second modulein the first enclosure in place of the first module and attaching thesecond module to said any other module to which the first module wasattached; and then re-operating the axial field rotary energy device.

Embodiments of each module can have only one orientation within theenclosure, such that each module can be installed or uninstalledrelative to the enclosure in singular manners. The purpose of suchdesigns is so the person doing work on the system cannot re-install newmodules into an existing system the wrong position. It can only be donein only one orientation. The method can occur while operation of theAFRED is suspended, and treatment of the first module occurs withoutinterrupting said any other module, and without modifying or impactingsaid any other module.

FIG. 27 depicts another embodiment of a PCB stator 311 for an axialfield rotary energy device, such as those disclosed herein. PCB stator311 comprises a substrate having one or more traces 313 that areelectrically conductive. In the version shown, PCB stator 311 compriseseight coils of traces 313. In addition, PCB stator 311 can comprise morethan one layer of traces 313. The traces 313 on each layer are co-planarwith the layer. In addition, the traces 313 are arrayed about a centralaxis 315 of the PCB stator.

FIG. 28 is an enlarged top view of a portion of the PCB stator of FIG.27. In the embodiment shown, each trace 313 comprises radial portions317 (relative to axis 315) and end turns 319 extending between theradial portions 317. Each trace 313 can be split with a slit 321. Insome versions, only radial portions 317 comprise slits 321. Slits 321can help reduce eddy current losses during operation. Eddy currentsoppose the magnetic field during operation. Reducing eddy currentsincreases magnetic strength and increases efficiency of the system. Incontrast, wide traces can allow eddy currents to build. The slits in thetraces 313 can reduce the opportunity for eddy currents to form. Theslits can force the current to flow through the traces 313 moreeffectively.

The axial field rotary energy device can comprise a “smart machine” thatincludes one or more sensors integrated therewith. In some embodiments,such a sensor can be configured to monitor, detect, or generate dataregarding operation of the axial field rotary energy device. In certainembodiments, the operational data can include at least one of power,temperature, rate of rotation, rotor position, or vibration data.

Versions of the axial field rotary energy device can comprise anintegrated machine that includes one or more control circuits integratedtherewith. Other versions of the axial field rotary energy device cancomprise a fully integrated machine that includes one or more sensorsand one or more control circuits integrated therewith. For example, oneor more sensors and/or control circuits can be integrated with the PCBand/or integrated with the housing. For motor embodiments, these controlcircuits can be used to drive or propel the machine. For example, insome motor embodiments, such a control circuit can include an inputcoupled to receive an external power source, and can also include anoutput coupled to provide a current flowing through one or more statorcoils. In some embodiments the control circuit is configured to supplytorque and/or torque commands to the machine. In some generatorembodiments, such a control circuit can include an input coupled toreceive the current flowing through the coil, and can also include anoutput coupled to generate an external power source.

For example, one or more sensors and/or control circuits can beintegrated with the PCB stator 311. FIG. 29 shows another exemplarystator 340 having integrated sensors (e.g., 342, 346) that are attachedto its uppermost PCB layer 47. One such sensor 342 is coupled to asecondary coil 344 that can be used to transmit/receive data to/from anexternal device, and can be also used to couple power to the sensor 342.In some embodiments the secondary coil can be configured to utilizemagnetic flux developed during operation to provide power for the sensor342. In some embodiments the secondary coil can be configured to receiveinductively coupled power from an external coil (not shown). Thesecondary coil 344 may also be referred to herein as a micro-coil, or aminiature coil, as in certain embodiments such a secondary coil can bemuch smaller than a stator coil 49, but no relative size inference isintended. Rather, such a secondary coil 344 is distinct from the statorcoils 49 that cooperate with the rotor magnets, as described above. Sucha secondary coil integrated with the PCB stator 311 can, in certainembodiments, be disposed on the PCB stator 311 (e.g., fabricated on, orattached to, its uppermost PCB layer 47). Such a secondary coilintegrated with the PCB stator 311 can, in certain embodiments, bedisposed within (i.e., embedded within) the PCB stator 311. In someembodiments, the secondary coil 344 provides power to a sensor connectedthereto. Such coupled power can be primary or auxiliary power for thesensor.

Sensor 346 is coupled to the first terminal 51 for one of the traces 49on the upper PCB layer 47, and can sense an operating parameter such asvoltage, temperature at that location, and can also be powered by theattached coil (e.g., one of the coils 49). Sensor 348 is coupled to anexternal terminal 350, and likewise can sense an operating parametersuch as voltage, temperature at that location, and can also be poweredby the voltage coupled to the external terminal 350. Sensor 350 isdisposed at an outer edge of the PCB stator 340, but is coupled to noconductor on the PCB layer 47.

In some embodiments, such a sensor can be embedded directly in one ofthe coils 49 and can be electrically powered directly by the coil 49. Insome embodiments, such a sensor can be powered and connected to the coil49 through a separate connection that is disposed on or within the PCBlayer 47, such as the connection between the first terminal 51 andsensor 346. Such a connection can be disposed on the PCB layer 47 ordisposed within the PCB (e.g., on an internal layer of the PCB). Inother embodiments, the sensor and/or circuitry can get power from anexternal power source. For example, one type of external power sourcecan be a conventional wall electrical socket which can be coupled to thehousing of the motor or generator.

The sensors can provide operators of generator or motor products withreal time operational data as well as, in certain embodiments,predictive data on various parameters of the product. This can includehow the equipment is operating, and how and when to schedulemaintenance. Such information can reduce product downtime and increaseproduct life. In some embodiments, the sensor can be integrated withinthe housing. In some examples, the sensors can be embedded within thePCB stator 340, as is shown in FIG. 30 (e.g., sensors 362, 366, 368,372, and coil 364).

One example of a sensor for these applications is a Hall effect sensor.Hall effect sensors are used for proximity switching, positioning, speeddetection, and current sensing applications. In its simplest form, theHall effect sensor operates as an analog transducer, directly returninga voltage.

Another example of a sensor is an optical sensor. Optical sensors canmeasure the intensity of electromagnetic waves in a wavelength rangebetween UV light and near infrared light. The basic measurement deviceis a photodiode. Combining a photodiode with electronics makes a pixel.In one example, the optical sensor can include an optical encoder thatuses optics to measure or detect the positions of the magnetic rotor.

Another example of a sensor is a thermocouple sensor to measuretemperature. Thermocouples comprise two wire legs made from differentmetals. The wires legs are welded together at one end, creating ajunction. The junction is where the temperature is measured. When thejunction experiences a change in temperature, a voltage is created.

Another optional sensor is an accelerometer. Accelerometers are anelectromechanical device used to measure acceleration forces. Suchforces can be static, like the continuous force of gravity or, as is thecase with many mobile devices, dynamic to sense movement or vibrations.Acceleration is the measurement of the change in velocity, or speeddivided by time.

A gyro sensor, which functions like a gyroscope, also can be employed inthese systems. Gyro sensors can be used to provide stability or maintaina reference direction in navigation systems, automatic pilots, andstabilizers.

The PCB stator 340 also can include a torque sensor. A torque sensor,torque transducer or torque meter is a device for measuring andrecording the torque on a rotating system, such as the axial fieldrotary energy device.

Another optional sensor is a vibration sensor. Vibration sensors canmeasure, display and analyze linear velocity, displacement andproximity, or acceleration. Vibration, even minor vibration, can be atelltale sign of the condition of a machine.

In various embodiments, the sensors depicted in FIG. 29 and FIG. 30 canalso represent control circuits integrated with the PCB stator 345. Suchcontrol circuits can be disposed on a surface of the PCB (analogously tothe sensors depicted in FIG. 29), disposed within (i.e., embeddedwithin) the PCB (analogously to the sensors depicted in FIG. 30), and/orintegrated with or within the housing (e.g., housing 203 in FIG. 18).

In some generator embodiments, the control circuit can implement powerconversion from an AC voltage developed in the stator coils to anexternal desired power source (e.g., an AC voltage having a differentmagnitude than the coils voltage, a DC voltage developed by rectifyingthe coils voltage). In some motor embodiments, the control circuit canimplement an integrated drive circuitry that can provide desired ACcurrent waveforms to the stator coils to drive the motor. In someexamples, the integrated drive can be a variable frequency drive (VFD),and can be integrated with the same housing as the motor. The sensorsand/or circuitry disclosed herein can be wirelessly or hard-wired to anyelement of, on or in the housing. Alternatively, the sensors and/orcircuitry can be located remotely relative to the housing.

Each of these sensors and control circuits can include a wirelesscommunication circuit configured to communicate with an external devicethrough a wireless network environment. Such wireless communication canbe unidirectional or bidirectional, and can be useful for monitoring astatus of the system, operating the system, communicating predictivedata, etc. The wireless communication via the network can be conductedusing, for example, at least one of long term evolution (LTE),LTE-advanced (LTE-A), code division multiple access (CDMA), widebandCDMA (WCDMA), universal mobile telecommunication system (UMTS), wirelessbroadband (WiBro), or global system for mobile communications (GSM), asa cellular communication protocol.

Additionally or alternatively, the wireless communication can include,for example, short-range communication. The short-range communicationcan be conducted by, for example, at least one of wireless fidelity(WFi), Bluetooth®, near field communication (NFC), or GNSS. GNSS caninclude, for example, at least one of global positioning system (GPS),Glonass®. global navigation satellite system, Beidou® navigationsatellite system, or Galileo®, the European global satellite-basednavigation system. In the present disclosure, the terms ‘GPS’ and ‘GNSS’are interchangeably used with each other. The network can be acommunication network, for example, at least one of a computer network(for example, local area network (LAN) or wide area network (WAN)), theInternet, or a telephone network.

In certain embodiments, such a wireless communication circuit can becoupled to a secondary coil (e.g., secondary coil 344) to communicatetelemetry information, such as the operational data described above.

FIGS. 31 and 32 show an embodiment of an assembly for mechanicallycoupling together stator segments 380 to form a stator. A clasp 382slides over portions of a mounting pad 381 on two adjacent statorsegments 380, which is secured by a pair of nuts on each of two bolts(e.g., bolt 384). The clasp 382 includes an alignment tab 392 that canbe positioned into a side wall slot 214 as described above. The innerdiameter edge of the two adjacent stator segments 380 slides into achanneled rotor spacer 390 in the shape of an annular ring. In someembodiments this rotor spacer 390 can ride on a thrust bearing with therotor to allow the rotor spacer 390 and stator to remain stationarywhile the rotor rotates. In other embodiments a rotor spacer asdescribed above (e.g., FIGS. 18, 20A-20H) can fit within the open centerof the channeled rotor spacer 390.

Electrical connection between adjacent stator segments 380, 381 can beimplemented using a wire 387 between respective circuits 386, 388.Circuit 386 can connect to a trace on the upper layer (or another layerusing a via) of the stator segment 380. Similarly, circuit 388 canconnect to a trace on any layer of the stator segment 381. Such circuits386, 388 can include any of the sensors described above (FIGS. 29-30),but can also merely provide an electrical connection from the respectivePCB to the wire 387. In other embodiments, electrical connection alsocan be made via the mounting surface of the PCB being a conductivematerial and connected to the coil and then coupling those componentsthrough the clasp, which also can include conductive material on theinner surface thereof.

Electrical connection can also be implemented using the clasp 382 incombination with an electrically conductive mounting pad 383. If themounting pad 383 is continuous and unbroken, the clasps 382 can providea common electrical connection around the circumference of the stator.If such mounting pads are discontinuous and broken into two pieces (asshown by the dash lines, with each piece coupled to a respectiveterminal of a trace on that segment, the clasps 382 can serially connectsuch stator segments.

The axial field rotary energy device is suitable for many applications.The PCB stator 340 can be configured for a desired power criteria andform factor for devices such as permanent magnet-type generators andmotors. Such designs are lighter in weight, easier to produce, easier tomaintain and more capable of higher efficiency.

Examples of permanent magnet generator (PMG) applications can include awind turbine generator, micro-generator application, permanent magnetdirect drive generator, steam turbine generator, hydro generator,thermal generator, gas generator, wood-fire generator, coal generator,high frequency generator (e.g., frequency over 60 Hz), portablegenerator, auxiliary power unit, automobiles, alternator, regenerativebraking device, PCB stator for regenerative braking device, back-up orstandby power generation, PMG for back up or standby power generation,PMG for military usage and a PMG for aerospace usage.

In other embodiments, examples of a permanent magnet motor (PMM) caninclude an AC motor, DC motor, servo motor, stepper motor, drone motor,household appliance, fan motor, microwave oven, vacuum machine,automobile, drivetrain for electric vehicle, industrial machinery,production line motor, internet of things sensors (IOT) enabled,heating, ventilation and air conditioning (HVAC), HVAC fan motor, labequipment, precision motors, military, motors for autonomous vehicles,aerospace and aircraft motors.

FIGS. 33 and 34 depict another embodiment of an axial field rotaryenergy device 401. In these examples, the device 401 can include any ofthe features, elements or components disclosed herein. The illustratedversion can include a housing (e.g., housing 203 in FIG. 18) having anaxis 405 with an axial direction. A stator assembly 411 can include aplurality of stator panels 445 that are discrete panels from each other.The stator panels 445 can be mechanically and stationarily coupled tothe housing. Each stator panel 445 can include a printed circuit board(PCB) having coils that are electrically conductive, as disclosedherein. Embodiments of each stator panel 445 can consist of a singleelectrical phase. The device 401 also can include rotors 442 rotatablymounted within the housing on opposite axial ends of the stator assembly411. The rotors 442 can be mechanically coupled together with acomponent, such as a rotor spacer 443. Versions of each rotor 442 caninclude magnets 437. In some examples, no rotor 442 is disposed betweenaxially adjacent ones of the stator panels 445.

The stator panels 445 can be coupled in an axially abuttingrelationship. Moreover, the stator panels 445 can be mechanicallycoupled directly to each other in the axially abutting relationship. Inaddition, the stator panels 445 can be rotationally aligned at a singleangle with respect to the axis 405. In some examples, the stator panels445 can be electrically coupled together to form a single electricalcircuit for the device 401. In other embodiments of the device 401, noaxial spacer is disposed between axially adjacent ones of the statorpanels 445. As shown and described for other examples herein, the coilsof the stator panels 445 can extend in a radial direction with respectto the axis 405, each coil can include edges that extend in the radialdirection, and the coil edges can be substantially parallel to eachother. In other words, the coils can have inner and outer opposing edgesthat are parallel to each other.

Embodiments of the device 401 can include the stator assembly 411 with aplurality of electrical phases. The stator panels 445 can berotationally offset from each other relative to the axis 405. In someexamples, the stator panels 445 are not electrically coupled together toform a single electrical circuit for the device 401. In one particularversion, the stator assembly 411 can consist of only three stator panels442. In another particular example, the rotors 442 can consist of onlytwo rotors 442. The device 401 can further include a spacer (not shown)of any type (e.g., metal, paper, etc.) disposed between axially adjacentones of the stator panels 445. Embodiments of the device 401 can furtherinclude axial spacers (not shown) between the stator assembly 411 andthe rotors 442. Versions of the axial spacers can set axial air gapspacings between the stator assembly 411 and the rotors 442.

As shown in FIG. 35, embodiments of the coils 459 can be asymmetricallyarrayed about the axis 405. In some versions, each stator panel 455 caninclude an inner radius IR, an outer radius OR and a slot S extendingcontinuously in a radial direction between the inner radius IR and theouter radius OR. In an example, the slot S can include a circumferentialwidth W, relative to the axis 405, that is not less than a diameter ofthe rotor spacer (e.g., rotor spacer 443 in FIG. 33) that couples therotors 442 together. Embodiments of the slot S can be defined bysidewalls 453 that are parallel to each other, and the circumferentialwidth W can be consistent from the inner radius IR to the outer radiusOR. In such versions, the slot S can be configured to remain void andunencumbered during operation of the device 401, such that no othercomponent is located within the slot S during operation of the device401.

Alternatively, as shown in FIG. 36, an alternate embodiment of the slotS can be defined by sidewalls 463 that are not parallel, and thecircumferential width W tapers from the inner radius IR to the outerradius OR. In some embodiments, at least one of the coils 469 of each ofthe stator panels 465 can be located on a stator panel segment 468 thatinclude another PCB that is mechanically and electrically coupled tosaid each of the stator panels 465, respectively. Examples of eachstator panel 465 can be configured to be individually removed from thestator assembly 411 (see, e.g., FIGS. 33 and 34) via the slot S withoutdisassembling the rotors 442 from the axial field rotary energy device401. In addition, respective ones of the stator panels 465 and statorpanel segments 468 can be mounted to each other in a co-planararrangement, for example.

In a particular embodiment, the device 401 can include a mismatchednumber of pluralities of stators panels and rotors. For example, thedevice can have two stator panels and one rotor, three stator panels andtwo rotors, five stator panels and two rotors, etc., In some versions,no rotor is interleaved within the stator assembly 411 (i.e., axiallydisposed between axially adjacent ones of the stator panels). Moreover,the device 401 can comprise a single electrical phase or more than oneelectrical phase. Other embodiments can include an enclosure with two ormore devices 401 (which can be identical) located within the enclosure.

FIG. 37 is an enlarged, partial top view of yet another embodiment of astator panel 475. Examples of the coils 476 of the stator panel 475 canhave a higher density of copper adjacent inner and outer diameterportions 477, 478, respectively, thereof, compared to radial portions479 thereof, which can be further spread apart than the inner and outerdiameter portions 477, 478.

FIG. 38 is an enlarged, partial top view of an alternate embodiment of astator panel 485. Examples of the stator panel 485 can have variablenumbers of slits within the radial traces 489 of its coils 486. Forexample, the radial traces can include two, three, four, five or moreslits within the same radial trace 489, as illustrated.

Other versions can include one or more of the following embodiments:

1. An axial field rotary energy device, comprising:

a rotor comprising an axis of rotation and a magnet;

a stator coaxial with the rotor, the stator comprising a printed circuitboard (PCB) having a plurality of PCB layers that are spaced apart in anaxial direction, each PCB layer comprises a coil having only twoterminals for electrical connections, each coil is continuous anduninterrupted between its only two terminals, each coil consists of asingle electrical phase, and one of the two terminals of each coil iselectrically coupled to another coil with a via to define a coil pair;and

each coil pair is electrically coupled to another coil pair with anothervia.

2. The axial field rotary energy device of any of these embodiments,wherein each PCB layer comprises a plurality of coils, and the coils ineach coil pair are co-planar and located on a same PCB layer.

3. The axial field rotary energy device of any of these embodiments,wherein the coils in each coil pair are located on different PCB layers.

4. The axial field rotary energy device of any of these embodiments,wherein at least two of the coils are electrically coupled in series.

5. The axial field rotary energy device of any of these embodiments,wherein at least two of the coils are electrically coupled in parallel.

6. The axial field rotary energy device of any of these embodiments,wherein at least two of the coils are electrically coupled in parallel,and at least two other coils are electrically coupled in series.

7. The axial field rotary energy device of any of these embodiments,wherein at least two of the coil pairs are electrically coupled inparallel.

8. The axial field rotary energy device of any of these embodiments,wherein at least two of the coil pairs are electrically coupled inseries.

9. The axial field rotary energy device of any of these embodiments,wherein at least two of the coil pairs are electrically coupled inparallel, and at least two other coil pairs are electrically coupled inseries.

10. The axial field rotary energy device of any of these embodiments,wherein each PCB layer comprises a PCB layer surface area, the coil oneach PCB layer comprises a plurality of coils having a coils surfacearea that is in a range of at least about 75% to about 99% of the PCBlayer surface area.

11. The axial field rotary energy device of any of these embodiments,wherein each PCB layer comprises a plurality of coils that are co-planarand symmetrically spaced apart about the axis, and the coils in adjacentPCB layers, relative to the axis, are circumferentially aligned witheach other relative to the axis to define symmetric stacks of coils inthe axial direction.

12. The axial field rotary energy device of any of these embodiments,wherein the stator consists of a single electrical phase.

13. The axial field rotary energy device of any of these embodiments,wherein the stator comprises at least two electrical phases.

14. The axial field rotary energy device of any of these embodiments,wherein each PCB layer comprises a plurality of coils for eachelectrical phase, and the coils for each electrical phase are angularlyoffset from each other with respect to the axis within each PCB layer todefine a desired phase angle shift between the electrical phases.

15. The axial field rotary energy device of any of these embodiments,wherein the stator comprises a single unitary panel.

16. The axial field rotary energy device of any of these embodiments,wherein each coil is coupled to another coil with only one via.

17. The axial field rotary energy device of any of these embodiments,wherein each coil pair is coupled to another coil pair with only onevia.

18. The axial field rotary energy device of any of these embodiments,wherein the via comprises a plurality of vias.

19. The axial field rotary energy device of any of these embodiments,wherein said another via comprises a plurality of vias.

20. The axial field rotary energy device of any of these embodiments,wherein the axial field rotary energy device is a generator.

21. The axial field rotary energy device of any of these embodiments,wherein the axial field rotary energy device is a motor.

22. The axial field rotary energy device of any of these embodiments,wherein the axial field rotary energy device comprises two or moreelectrical phases and two or more external terminals.

23. The axial field rotary energy device of any of these embodiments,wherein the coils are identical to each other.

24. The axial field rotary energy device of any of these embodiments,wherein at least two of the coils are not identical to each other anddiffer from each by at least one of size or shape.

25. An axial field rotary energy device, comprising:

a rotor comprising an axis of rotation and a magnet; and

a stator coaxial with the rotor, the stator comprising a printed circuitboard (PCB) having a plurality of PCB layers that are spaced apart in anaxial direction, each PCB layer comprises a coil, and the plurality ofPCB layers comprise:

a plurality of coil layer pairs, the coils in each coil layer pair areon different PCB layers, at least two of the coil layer pairs arecoupled together in parallel, and at least another two of the coil layerpairs are coupled together in series.

26. The axial field rotary energy device of any of these embodiments,wherein the stator comprises at least two electrical phases.

27. The axial field rotary energy device of any of these embodiments,wherein each PCB layer comprises a plurality of coils for eachelectrical phase, and the coils for each electrical phase are angularlyoffset from each other with respect to the axis within each PCB layer todefine a desired phase angle shift between the electrical phases.

28. The axial field rotary energy device of any of these embodiments,wherein each coil consists of a single electrical phase.

29. An axial field rotary energy device, comprising:

a rotor comprising an axis of rotation and a magnet;

a stator coaxial with the rotor, the stator comprising a printed circuitboard (PCB) having a first PCB layer and a second PCB layer that arespaced apart from each other in an axial direction, each PCB layercomprises a coil that is continuous, and each coil has only twoterminals for electrical connections; and [0181] only one via toelectrically couple the coils through one terminal of each of the coils.

30. An axial field rotary energy device, comprising:

a rotor comprising an axis of rotation and a magnet;

a stator coaxial with the rotor, the stator comprises a printed circuitboard (PCB) consisting of a single unitary panel having at least twoelectrical phases, the PCB comprises a plurality of PCB layers that arespaced apart in an axial direction, each PCB layer comprises a pluralityof coils, each coil has only two terminals for electrical connections,each coil is continuous and uninterrupted between its only twoterminals, each coil consists of a single electrical phase, and one ofthe two terminals of each coil is electrically coupled to another coilwith only one via to define a coil pair, each coil pair is electricallycoupled to another coil pair with another only one via;

the coils in each PCB layer are co-planar and symmetrically spaced apartabout the axis, and the coils in adjacent PCB layers arecircumferentially aligned with each other to define symmetric stacks ofcoils in the axial direction; and

each PCB layer comprises a plurality of coils for each electrical phase,and the coils for each electrical phase are angularly offset from eachother with respect to the axis within each PCB layer to define a desiredphase angle shift between the electrical phases.

1. An axial field rotary energy device, comprising:

a rotor comprising an axis of rotation and a magnet; and

a stator coaxial with the rotor, the stator comprises a plurality ofstator segments coupled together about the axis, each stator segmentcomprises a printed circuit board (PCB) having a PCB layer comprising acoil, and each stator segment comprises only one electrical phase.

2. The axial field rotary energy device of any of these embodiments,wherein the stator consists of only one electrical phase.

3. The axial field rotary energy device of any of these embodiments,wherein the stator comprises a plurality of electrical phases.

4. The axial field rotary energy device of any of these embodiments,wherein the coils are identical to each other.

5. The axial field rotary energy device of any of these embodiments,wherein each PCB layer comprises a plurality of coils that are co-planarand angularly spaced apart from each other relative to the axis.

6. The axial field rotary energy device of any of these embodiments,wherein each stator segment comprises a plurality of PCB layers, each ofwhich is configured to provide said only one electrical phase.

7. The axial field rotary energy device of any of these embodiments,wherein each PCB layer on each stator segment comprises a plurality ofcoils that are co-planar and configured to provide said only oneelectrical phase.

8. The axial field rotary energy device of any of these embodiments,wherein each coil comprises radial traces that extend from about aninner diameter of the PCB to about an outer diameter of the PCB.

9. The axial field rotary energy device of any of these embodiments,wherein each coil comprises a trace that is continuous from an outermosttrace portion to a concentric innermost trace portion, and the coilscomprise radial elements having linear sides and turns.

10. The axial field rotary energy device of any of these embodiments 9,wherein each coil comprises only linear traces that are continuous froman outermost trace to a concentric innermost trace, no trace of the PCBlayers is non-linear, and said each coil comprises corners to join theonly linear traces.

11. The axial field rotary energy device of any of these embodiments 0,wherein each PCB layer comprises a PCB layer surface area, the coil oneach PCB layer comprises a plurality of coils having a coils surfacearea that is in a range of at least about 75% to about 99% of the PCBlayer surface area.

12. The axial field rotary energy device of any of these embodiments 1,wherein each PCB layer comprises a plurality of coils that are co-planarand symmetrically spaced apart about the axis, and the coils in adjacentPCB layers are circumferentially aligned with each other relative to theaxis to define symmetric stacks of coils in an axial direction.

13. An axial field rotary energy device, comprising:

a rotor comprising an axis of rotation and a magnet;

a stator coaxial with the rotor, the stator comprises a plurality ofstator segments coupled together about the axis, each stator segmentcomprises a printed circuit board (PCB) having a plurality of PCB layerseach comprising a coil, the PCB layers are spaced apart from each otherin an axial direction, each of the PCBs has an even number of PCBlayers, the PCB layers comprise layer pairs, each layer pair is definedas two PCB layers that are electrically coupled together with a via, andeach layer pair is coupled to another layer pair with another via.

14. The axial field rotary energy device of any of these embodiments,wherein at least one of the PCB layers is electrically coupled toanother PCB layer in series.

15. The axial field rotary energy device of any of these embodiments,wherein at least one of the PCB layers is electrically coupled toanother PCB layer in parallel.

16. The axial field rotary energy device of any of these embodiments,wherein at least one layer pair is electrically coupled to another layerpair in series.

17. The axial field rotary energy device of any of these embodiments,wherein at least one layer pair is electrically coupled to another layerpair in parallel.

18. The axial field rotary energy device of any of these embodiments,wherein at least one of the layer pairs comprises two PCB layers thatare axially spaced apart from and axially adjacent to each other.

19. The axial field rotary energy device of any of these embodiments,wherein at least one of the layer pairs comprises two PCB layers thatare not axially adjacent to each other.

20. The axial field rotary energy device of any of these embodiments,wherein at least one of the layer pairs is axially adjacent to the layerpair to which said at least one of the layer pairs is electricallycoupled.

21. The axial field rotary energy device of any of these embodiments,wherein at least one of the layer pairs is not axially adjacent to thelayer pair to which said at least one of the layer pairs is electricallycoupled.

22. The axial field rotary energy device of any of these embodiments,wherein the coils are identical to each other.

23. The axial field rotary energy device of any of these embodiments,wherein at least two of the coils are not identical to each other anddiffer from each by at least one of size, shape or architecture.

24. An axial field rotary energy device, comprising:

a rotor comprising an axis of rotation and a magnet; and

a stator coaxial with the rotor, the stator comprises a plurality ofstator segments and a plurality of electrical phases, each statorsegment comprises a printed circuit board (PCB) having at least one PCBlayer with a coil, and each stator segment comprises only one electricalphase.

25. An axial field rotary energy device, comprising:

a rotor comprising an axis of rotation and a magnet;

a stator coaxial with the rotor, the stator comprises a plurality ofstator segments coupled together about the axis, each stator segmentcomprises a printed circuit board (PCB) having a plurality of PCB layerseach comprising coils, the PCB layers are spaced apart from each otherin an axial direction, each of the PCBs has an even number of PCBlayers, the PCB layers comprise layer pairs, and each layer pair isdefined as two PCB layers that are electrically coupled together; and

the coils in each PCB layer are co-planar and angularly andsymmetrically spaced apart from each other about the axis, and the coilsin adjacent PCB layers are circumferentially aligned with each other todefine symmetric stacks of coils in the axial direction.

26. The axial field rotary energy device of any of these embodiments,wherein the stator consists of only one electrical phase, and the coilsare identical to each other.

27. The axial field rotary energy device of any of these embodiments,wherein the stator comprises a plurality of electrical phases.

28. The axial field rotary energy device of any of these embodiments,wherein each PCB layer is configured to provide only one electricalphase.

29. The axial field rotary energy device of any of these embodiments,wherein the coils on each PCB layer on each stator segment areconfigured to provide said only one electrical phase.

30. The axial field rotary energy device of any of these embodiments,wherein the axial field rotary energy devices consists of a singleelectrical phase.

1. A module for an axial field rotary energy device, comprising: [0227]a housing having coupling structures configured to mechanically couplethe housing to a second housing of a second module, and electricalelements configured to electrically couple the housing to the secondhousing;

a rotor rotatably mounted to the housing, and the rotor comprises anaxis and a magnet; and

a stator mounted to the housing coaxially with the rotor, and the statorcomprises a printed circuit board (PCB) having a PCB layer comprising acoil.

2. The module of any of these embodiments, wherein the rotor and thestator are located inside and surrounded by the housing.

3. The module of any of these embodiments, wherein the rotor comprises aplurality of rotors, the magnet comprises a plurality of magnets, andthe stator comprises a plurality of stators, and each of the statorscomprises a plurality of PCB layers, and each PCB layer comprises aplurality of coils.

4. The module of any of these embodiments, wherein the module isconfigured to be directly coupled to a frame, and the module isconfigured to be indirectly coupled to the second module.

5. The module of any of these embodiments, wherein the housing comprisesa side wall that orients the stator at a desired angular orientationwith respect to the axis.

6. The module of any of these embodiments, wherein the stator comprisesa plurality of stators, and the side wall comprises a plurality of sidewall segments that angularly offset the plurality of stators at desiredangular orientations with respect to the axis.

7. The module of any of these embodiments, wherein each side wallsegment comprises a radial inner surface having a slot formed therein,the slot receives and maintains the desired angular orientation of thestator with respect to the axis, and the slots, collectively, hold outeredges of the stator at an air gap spacing between the stator and therotor.

8. The module of any of these embodiments, wherein the stator is aircooled and is not liquid cooled.

9. The module of any of these embodiments, wherein the PCB layercomprises a plurality of PCB layers, each having a plurality of coils,each coil has only two terminals, each coil is continuous anduninterrupted between its only two terminals, and each coil iselectrically coupled to another coil with a via.

10. The module of any of these embodiments, wherein two coils arecoupled together to define a coil pair, and each coil pair iselectrically coupled to another coil pair with another via.

11. The module of any of these embodiments, wherein the coils in eachcoil pair are located on different PCB layers.

12. The module of any of these embodiments, wherein each coil is coupledto another coil with only one via, and each coil pair is coupled toanother coil pair with only one another via.

13. The module of any of these embodiments, wherein the stator comprisesa plurality of stator segments, each of which comprises a PCB.

14. The module of any of these embodiments, wherein the stator consistsof only one electrical phase.

15. The module of any of these embodiments, wherein the stator comprisesa plurality of electrical phases.

16. A module for an axial field rotary energy device, comprising: [0245]a housing having coupling structures configured to mechanically couplethe housing to a second housing of a second module, and electricalelements configured to electrically couple the housing to the secondhousing;

a plurality of rotors rotatably mounted to the housing and the rotorscomprise an axis and magnets; and

a plurality of stators mounted to the housing coaxially with the rotors,each stator comprises a printed circuit board (PCB) having a PCB layercomprising a coil, the stators are electrically coupled together insidethe housing.

17. A module for an axial field rotary energy device, comprising: [0249]a housing having coupling structures configured to mechanically couplethe housing to a second housing of a second module, and electricalelements configured to electrically couple the housing to the secondhousing;

rotors rotatably mounted to the housing relative to an axis, and eachthe rotor comprises magnets;

stators mounted to the housing coaxially with the rotors, each of thestators comprises a printed circuit board (PCB) having PCB layers, andeach PCB layer comprises coils; and

the housing comprises a plurality of side wall segments that orient thestators at desired angular orientations with respect to the axis, andangularly offset the stators at desired phase angles, wherein the sidewall segments comprise radial inner surfaces having slots formedtherein, the slots maintain the desired angular orientation and axialspacing of respective ones of the stators, and the slots, collectively,hold outer edges of the stators at desired air gap spacings between thestators and rotors.

18. The module of any of these embodiments, wherein the rotors andstators are located inside and surrounded by the housing; and furthercomprising:

a frame, the module is configured to be directly coupled to the frame,and the module is configured to be indirectly coupled to the secondmodule.

19. The module of any of these embodiments, wherein each coil has onlytwo terminals, each coil is continuous and uninterrupted between itsonly two terminals, and each coil is electrically coupled to anothercoil with a via.

20. The module of any of these embodiments, wherein each coil is coupledto another coil with only one via.

21. The module of any of these embodiments, wherein two coils arecoupled together to define a coil pair, and each coil pair iselectrically coupled to another coil pair with another via.

22. The module of any of these embodiments, wherein the module comprisesat least one of:

the coils in each coil pair are located on different PCB layers; or

each coil pair is coupled to another coil pair with only one via.

23. The module of any of these embodiments, wherein each statorcomprises a plurality of stator segments, and each of the statorsegments comprises a PCB.

24. The module of any of these embodiments, wherein each stator consistsof only one electrical phase.

25. The module of any of these embodiments, wherein each statorcomprises a plurality of electrical phases.

26. A module for an axial field rotary energy device, comprising: [0265]a housing having an axis; [0266] rotors rotatably mounted to the housingabout the axis, and each rotor comprises a magnet;

stators mounted to the housing coaxially with the rotors, each statorcomprises a printed circuit board (PCB) having a PCB layer comprising acoil, and each stator consists of a single electrical phase; and wherein

selected ones of the stators are angularly offset from each other withrespect to the axis at desired phase angles, such that the modulecomprises more than one electrical phase.

27. The module of any of these embodiments, wherein the housingcomprises a side wall having a plurality of side wall segments.

28. The module of any of these embodiments, wherein each side wallsegment comprises a slot in an inner surface thereof, the side wallsegments engage and orient the stators at desired angular orientationswith respect to the axis, each stator is angularly offset with respectto other ones of stators at the desired phase angles, the stators seatin the slots in the side wall segments, and the slots, collectively,hold outer edges of the stators at desired air gap spacings between thestators and rotors.

29. The module of any of these embodiments, wherein each stator consistsof only one PCB.

30. The module of any of these embodiments, wherein each statorcomprises two or more PCBs that are coupled together to form eachstator.

1. A system, comprising:

a plurality of modules comprising axial field rotary energy devices, themodules are connected together for a desired power input or output, andeach module comprises:

a housing having an axis, the housing is mechanically coupled to atleast one other module, and the housing is electrically coupled to saidat least one other module;

rotors rotatably mounted to the housing and each rotor comprisesmagnets; and

stators, each comprising a printed circuit board (PCB) having PCB layerscomprising coils.

2. The system of any of these embodiments, wherein the modules areidentical to each other.

3. The system of any of these embodiments, wherein at least two of themodules differ from each other by at least one of: power output, numberof rotors, number of magnets, number of stators, number of PCBs, numberof PCB layers, number of coils or angular orientation with respect tothe axis.

4. The system of any of these embodiments, wherein the modules aredirectly coupled to each other.

5. The system of any of these embodiments, wherein the modules areindirectly coupled to each other.

6. The system of any of these embodiments, wherein each module compriseslatches that mechanically secure the modules, and the latches aresymmetrically arrayed with respect to the axis.

7. The system of any of these embodiments, wherein one of the modulescomprises a first module that is axially connected to another module,and the first module differs structurally from said another module.

8. The system of any of these embodiments, wherein the modules arecoaxial and mounted to keyed shafts that mechanically couple themodules.

9. The system of any of these embodiments, further comprising anenclosure, and the modules are mounted and coupled together inside theenclosure.

10. The system of any of these embodiments, wherein the enclosurecomprises a plurality of enclosures, each mechanically coupled to atleast one other enclosure, and electrically coupled to said at least oneother enclosure.

11. The system of any of these embodiments, wherein each stator consistsof a single electrical phase, and selected ones of the stators areoffset from each other at desired electrical phase angles with respectto the axis.

12. The system of any of these embodiments, each stator comprises aplurality of electrical phases.

13. The system of any of these embodiments, wherein each modulecomprises a single electrical phase, and the modules are angularlyoffset from each other at desired electrical phase angles with respectto the axis.

14. The system of any of these embodiments, wherein each modulecomprises a plurality of electrical phases, and the modules areangularly offset from each other at desired electrical phase angles withrespect to the axis.

15. The system of any of these embodiments, wherein the modules areangularly aligned with each other relative to the axis, such that allrespective phase angles of the modules also are angularly aligned.

16. An assembly, comprising:

modules comprising axial field rotary energy devices, the modules aremechanically and electrically connected to each other for a desiredpower input or output, and each module consists of a single electricalphase;

17. an enclosure inside which the modules are mounted and coupled; andeach module comprises:

a housing having an axis and mechanically coupled to at least one othermodule, and electrically coupled to said at least one other module;

rotors rotatably mounted to the housing and the rotors comprise magnets;and

stators, each stator comprises a printed circuit board (PCB) having PCBlayers, and each PCB layer comprises coils.

17. The assembly of any of these embodiments, wherein the modules areidentical to each other.

18. The assembly of any of these embodiments, wherein at least two ofthe modules differ from each other by at least one of: power output,number of rotors, number of magnets, number of stators, number of PCBs,number of PCB layers, number of coils or angular orientation withrespect to the axis.

19. The assembly of any of these embodiments, wherein the modules aredirectly coupled to each other.

20. The assembly of any of these embodiments, wherein the modules areindirectly coupled to each other.

21. The assembly of any of these embodiments, wherein each modulecomprises latches that mechanically secure the module to another module,and the latches are symmetrically arrayed with respect to the axis.

22. The assembly of any of these embodiments, wherein one of the modulescomprises a first module that is axially connected to another module,and the first module differs structurally from said another module.

23. The assembly of any of these embodiments, wherein the modules arecoaxial and mounted to keyed shafts that mechanically couple themodules.

24. The assembly of any of these embodiments, wherein the enclosurecomprises a plurality of enclosures, each having coupling structuresthat mechanically couple the enclosure to at least one other enclosure,and electrical elements that electrically couple the enclosure to saidat least one other enclosure.

25. The assembly of any of these embodiments, wherein the modules areangularly offset from each other at desired electrical phase angles withrespect to the axis.

26. An assembly, comprising:

a plurality of modules comprising axial field rotary energy devices, themodules are identical and interchangeably connectable to each other fora desired power input or output, and the assembly is a generator or amotor that consists of a single electrical phase;

an enclosure inside which the modules are mounted and coupled; and eachmodule comprises:

a housing having an axis, coupling structures that mechanically couplethe housing to at least one other module, and electrical elements thatelectrically couple the housing to at least one other module;

a plurality of rotors rotatably mounted to the housing and the rotorscomprise magnets; and

a plurality of stators, each comprising a printed circuit board (PCB)having a plurality of PCB layers, and each PCB layer comprises aplurality of coils.

27. The assembly of any of these embodiments, wherein the enclosurecomprises a plurality of enclosures, each having coupling structuresthat mechanically couple the enclosure to at least one other enclosure,and electrical elements that electrically couple the enclosure to saidat least one other enclosure.

28. The assembly of any of these embodiments, wherein the modules areangularly offset from each other at desired electrical phase angles withrespect to the axis.

29. A method of maintaining an axial field rotary energy device, themethod comprising:

(a) providing an enclosure having a plurality of modules, each modulecomprising a housing, a rotor rotatably mounted to the housing, therotor comprises an axis and a magnet, a stator mounted to the housingcoaxially with the rotor, and the stator comprises a printed circuitboard (PCB);

(b) mechanically and electrically coupling the modules;

(c) operating the axial field rotary energy device;

(d) detecting an issue with a first module and stopping operation of theaxial field rotary energy device;

(e) opening the enclosure and disassembling the first module from theenclosure and any other module to which the first module is attached;

(f) installing a second module in the enclosure in place of the firstmodule and attaching the second module to said any other module to whichthe first module was attached; and then

(g) re-operating the axial field rotary energy device.

30. The method of any of these embodiments, further comprising:

detecting an issue with a first stator in a first module and stoppingoperation of the axial field rotary energy device;

opening the first module and disassembling the first stator from thefirst module; [0326] installing a second stator in the first module inplace of the first stator; and then [0327] re-operating the axial fieldrotary energy device.

1. An axial field rotary energy device, comprising:

a housing;

a rotor mounted inside the housing, the rotor having an axis of rotationand a magnet;

a stator mounted inside the housing coaxial with the rotor, the statorcomprising a printed circuit board (PCB) having a PCB layer with a coil;and

a sensor integrated within the housing, wherein the sensor is configuredto monitor, detect or generate data regarding operation of the axialfield rotary energy device.

2. The axial field rotary energy device of any of these embodiments,wherein the operational data comprises at least one of power,temperature, rate of rotation, rotor position, or vibration data.

3. The axial field rotary energy device of any of these embodiments,wherein the sensor comprises at least one of a Hall effect sensor,encoder, optical sensor, thermocouple, accelerometer, gyroscope orvibration sensor.

4. The axial field rotary energy device of any of these embodiments,wherein:

the axial field rotary energy device is a motor;

the sensor is configured to provide information regarding a position ofthe rotor in the motor; and

the sensor is mounted to the housing.

5. The axial field rotary energy device of any of these embodiments,wherein the sensor includes a wireless communication circuit.

6. The axial field rotary energy device of any of these embodiments,wherein the sensor is configured to transmit operational data of theaxial field rotary energy device to an external device.

7. The axial field rotary energy device of any of these embodiments,wherein the sensor is Integrated with the PCB.

8. The axial field rotary energy device of any of these embodiments,wherein the sensor is embedded directly in the coil and is configured tobe electrically powered directly by the coil.

9. The axial field rotary energy device of any of these embodiments,wherein the sensor is configured to be powered and connected to the coilthrough a separate electrical connection that is disposed on or withinthe PCB.

10. The axial field rotary energy device of any of these embodiments,further comprising a secondary coil integrated with the PCB that iscoupled to the sensor.

11. The axial field rotary energy device of any of these embodiments,wherein the secondary coil is configured to utilize magnetic fluxdeveloped during operation to provide power for the sensor.

12. An axial field rotary energy device, comprising:

a housing;

a rotor mounted inside the housing, the rotor having an axis of rotationand a magnet;

a stator mounted inside the housing coaxial with the rotor, the statorcomprising a printed circuit board (PCB) having a PCB layer with a coil;and

a control circuit mounted within the housing, wherein the controlcircuit is coupled to the coil and comprises at least one of an inputcoupled to receive a current flowing through the coil, or an outputcoupled to provide the current flowing through the coil.

13. The axial field rotary energy device of any of these embodiments,wherein the control circuit is integrated with the PCB.

14. The axial field rotary energy device of any of these embodiments,wherein:

the axial field rotary energy device is a generator; and

the control circuit comprises an input coupled to receive the currentflowing through the coil, and further comprises an output coupled togenerate an external power source.

15. The axial field rotary energy device of any of these embodiments,wherein:

the axial field rotary energy device is a motor; and

the control circuit comprises an input coupled to receive an externalpower source, and further comprises an output coupled to provide thecurrent flowing through the coil.

16. The axial field rotary energy device of any of these embodiments,further comprising a sensor integrated within the housing, wherein:

the sensor is configured to provide information regarding a position ofthe rotor in the motor; and

the sensor is mounted to the housing.

17. An axial field rotary energy device, comprising:

a housing;

a rotor mounted inside the housing, the rotor having an axis of rotationand a magnet;

a stator mounted inside the housing coaxial with the rotor, the statorcomprising a printed circuit board (PCB) having a PCB layer with a coil;

a sensor integrated with the PCB; and

a secondary coil disposed on or within the PCB and coupled to thesensor.

18. The axial field rotary energy device of any of these embodiments,wherein the sensor is configured to be powered and connected to the coilthrough a separate electrical connection that is disposed on or withinthe PCB; and the sensor is configured to transmit operational data ofthe axial field rotary energy device to an external device using thesecondary coil.

19. The axial field rotary energy device of any of these embodiments,wherein the secondary coil is configured to utilize magnetic fluxdeveloped during operation to provide power for the sensor, and whereinthe sensor is not otherwise connected to the coil.

20. The axial field rotary energy device of any of these embodiments,wherein:

the sensor comprises at least one of a Hall effect sensor, encoder,optical sensor, thermocouple, accelerometer, gyroscope or vibrationsensor; and

the sensor includes a wireless communication circuit.

1. An axial field rotary energy device, comprising:

a rotor comprising an axis of rotation and a plurality of magnets, eachmagnet extends in a radial direction relative to the axis, and eachmagnet comprises a magnet radial edge;

a stator coaxial with the rotor, the stator comprises a plurality ofprinted circuit board (PCB) layers each having a plurality of coils, andeach coil comprises a coil radial edge; and

when radial edge portions of the magnets and coils rotationally alignrelative to the axis, the magnet radial edges and coil radial edges arenot parallel and are angularly skewed relative to each other.

2. The axial field rotary energy device of any of these embodiments,wherein the angular skew is at least about 0.1 degrees.

3. The axial field rotary energy device of any of these embodiments,wherein the angular skew is at least about 1 degree.

4. The axial field rotary energy device of any of these embodiments,wherein the angular skew is not greater than about 25 degrees.

5. The axial field rotary energy device of any of these embodiments,wherein the magnet radial edges and coil radial edges are leading radialedges or trailing radial edges of the magnets and coils, respectively.

6. The axial field rotary energy device of any of these embodiments,wherein each of the magnet radial edges and coil radial edges arelinear, and no portions of the magnet radial edges and coil radial edgesare parallel when the radial edge portions of the magnets and coilsrotationally align with respect to the axis.

7. The axial field rotary energy device of any of these embodiments,wherein when the radial edge portions of the magnets and coilsrotationally align, at least some portions of the magnet radial edgesand coil radial edges are parallel to each other.

8. The axial field rotary energy device of any of these embodiments,wherein the magnet radial edges and coil radial edges are not entirelylinear.

9. An axial field rotary energy device, comprising:

a rotor comprising an axis of rotation and magnets, and each magnet hasa magnet radial edge;

a stator coaxial with the rotor, the stator comprises a plurality ofstator segments coupled together about the axis, each stator segmentcomprises a printed circuit board (PCB) having a PCB layer comprising acoil, and each coil has a coil radial edge; and

when radial edge portions of the magnets and coils rotationally alignrelative to the axis, the magnet radial edges and coil radial edges arenot parallel and are angularly skewed relative to each other.

10. The axial field rotary energy device of any of these embodiments,wherein the angular skew is at least about 0.1 degrees.

11. The axial field rotary energy device of any of these embodiments,wherein the angular skew is at least about 1 degree.

12. The axial field rotary energy device of any of these embodiments,wherein the angular skew is not greater than about 25 degrees.

13. The axial field rotary energy device of any of these embodiments,wherein said at least portions of the magnet radial edges and coilradial edges are leading radial edges or trailing radial edges of themagnets and coils, respectively.

14. The axial field rotary energy device of any of these embodiments,wherein each of the magnet radial edges and coil radial edges arelinear, and no portions of the magnet radial edges and coil radial edgesare parallel when said at least portions of the magnets and coilsrotationally align.

15. The axial field rotary energy device of any of these embodiments,wherein when said at least portions of the magnets and coilsrotationally align, at least portions of the magnet radial edges andcoil radial edges are parallel to each other.

16. The axial field rotary energy device of any of these embodiments,wherein the magnet radial edges and coil radial edges are not entirelylinear.

17. A module for an axial field rotary energy device, comprising: [0395]a housing configured to mechanically couple the housing to a secondhousing of a second module, and electrically couple the housing to thesecond housing;

a rotor rotatably mounted to the housing, the rotor comprises an axisand a magnet, and the magnet has a magnet radial edge;

a stator mounted to the housing coaxially with the rotor, the statorcomprises a printed circuit board (PCB) having a PCB layer with a coil,and the coil has a coil radial edge; and

when radial edge portions of the magnet and coil rotationally alignrelative to the axis, at least radial edge portions of the magnet radialedge and coil radial edge are not parallel and are angularly skewedrelative to each other.

18. The axial field rotary energy device of any of these embodiments,wherein the angular skew is at least about 0.1 degrees, and the angularskew is not greater than about 25 degrees.

19. The axial field rotary energy device of any of these embodiments,wherein the magnet radial edge and coil radial edge are a leading radialedge or trailing radial edge of the magnet and coil, respectively.

20. The axial field rotary energy device of any of these embodiments,wherein the magnet radial edge and coil radial edge are linear, and noportions of the magnet radial edge and coil radial edge are parallelwhen the radial edge portions of the magnet and coil rotationally align.

1. An axial field rotary energy device, comprising:

a housing;

a rotor mounted inside the housing, the rotor having an axis of rotationand a magnet;

a stator mounted inside the housing coaxial with the rotor, the statorcomprising a printed circuit board (PCB) having a PCB layer with a tracethat is electrically conductive, the trace comprises radial traces thatextend in a radial direction relative to the axis and end turn tracesthat extend between the radial traces, and the trace comprises slitsthat extends through at least some portions of the trace.

2. The axial field rotary energy device of any of these embodiments,wherein the slits are in only the radial traces.

3. The axial field rotary energy device of any of these embodiments,wherein each of the slits is linear.

4. The axial field rotary energy device of any of these embodiments,wherein each of the slits is only linear, and the slits comprise nonon-linear portions.

5. The axial field rotary energy device of any of these embodiments,wherein the trace is tapered in the radial direction relative to theaxis.

6. The axial field rotary energy device of any of these embodiments,wherein the trace comprises an outer width that is adjacent an outerdiameter of the PCB and in a plane that is perpendicular to the axis,the trace comprises an inner width that is adjacent an inner diameter ofthe PCB and in the plane, and the outer width is greater than the innerwidth.

7. The axial field rotary energy device of any of these embodiments,wherein the trace comprises inner and outer opposing edges, andentireties of the inner and outer opposing edges are not parallel toeach other.

8. The axial field rotary energy device of any of these embodiments,wherein only the radial traces are tapered.

9. The axial field rotary energy device of any of these embodiments,wherein the trace comprises inner and outer opposing edges that areparallel to each outer.

10. The axial field rotary energy device of any of these embodiments,wherein the end turn traces are tapered.

11. The axial field rotary energy device of any of these embodiments,wherein the PCB layer comprises a PCB layer surface area, the trace onthe PCB layer comprises a trace surface area that is in a range of atleast about 75% to about 99% of the PCB layer surface area.

12. An axial field rotary energy device, comprising:

a housing;

a rotor mounted inside the housing, the rotor having an axis of rotationand a magnet; and

a stator mounted inside the housing coaxial with the rotor, the statorcomprising a printed circuit board (PCB) having a PCB layer with coils,each coil comprises traces, at least some of the traces are tapered withinner and outer opposing edges that are not parallel to each other, andthe traces comprise an outer width that is adjacent an outer diameter ofthe PCB and in a plane that is perpendicular to the axis, the tracescomprise an inner width that is adjacent an inner diameter of the PCBand in the plane, and the outer width is greater than an inner width.

13. The axial field rotary energy device of any of these embodiments,the coils comprise slits that extend through at least some portions ofthe traces.

14. The axial field rotary energy device of any of these embodiments,the traces comprise radial traces that extend in a radial directionrelative to the axis and end turn traces that extend between the radialtraces.

15. The axial field rotary energy device of any of these embodiments,wherein only the radial traces are tapered.

16. The axial field rotary energy device of any of these embodiments,further comprising slits only in the radial traces.

17. The axial field rotary energy device of any of these embodiments,wherein each of the slits is only linear, and the slits comprise nonon-linear portions.

18. An axial field rotary energy device, comprising:

a housing;

a rotor mounted inside the housing, the rotor having an axis of rotationand a magnet; and

a stator mounted inside the housing coaxial with the rotor, the statorcomprising a printed circuit board (PCB) having a PCB layer with coils,each coil comprises traces, at least some of the traces are tapered, thetraces comprise radial traces that extend in a radial direction relativeto the axis and end turn traces that extend between the radial traces,and only the radial traces are tapered.

19. The axial field rotary energy device of any of these embodiments,further comprising linear slits only in the radial traces, the linearslits are only linear, and the linear slits comprise no non-linearportions.

20. The axial field rotary energy device of any of these embodiments,wherein at least some of the tapered radial traces comprise inner andouter opposing edges that are not parallel to each other, the tracescomprise an outer width that is adjacent an outer diameter of the PCBand in a plane that is perpendicular to the axis, the traces comprise aninner width that is adjacent an inner diameter of the PCB and in theplane, and the outer width is greater than an inner width.

1. An axial field rotary energy device, comprising: [0432] a housinghaving an axis with an axial direction; [0433] a stator assemblycomprising a plurality of stator panels that are axially-stacked anddiscrete panels from each other, the stators panels are mechanically andstationarily coupled to the housing, each stator panel comprises arespective printed circuit board (PCB) having a respective plurality ofcoils that are electrically conductive and interconnected within therespective PCB, wherein the respective PCB is configured so that anelectrical current that flows through any one of the respectiveplurality of coils likewise flows through all of the respectiveplurality of coils, such that each stator panel consists of a singleelectrical phase; and [0434] rotors rotatably mounted within the housingon opposite axial ends of the stator assembly, the rotors aremechanically coupled together with a rotor spacer, each rotor comprisesmagnets, and no rotor is disposed between axially adjacent ones of thestator panels.

2. The device of any of these embodiments, wherein the stator panels arecoupled in a substantially axially abutting relationship.

3. The device of any of these embodiments, wherein the stator panels aremechanically coupled directly to each other in an axially abuttingrelationship.

4. The device of any of these embodiments, wherein the stator panels arerotationally aligned at a single angle with respect to the axis.

5. The device of any of these embodiments, wherein the stator panels areelectrically coupled together to form a single electrical circuit forthe device.

6. The device of any of these embodiments, wherein no axial spacer isdisposed between axially adjacent ones of the stator panels.

7. The device of any of these embodiments, wherein the coils extend in agenerally radial direction with respect to the axis, each coil comprisesedges that extend in the radial direction, and the coil edges aresubstantially parallel to each other.

8. The device of any of these embodiments, wherein the stator assemblycomprises a plurality of electrical phases, and the stator panels arerotationally offset from each other, relative to the axis, at a desiredangle.

9. The device of any of these embodiments, wherein the stator panels areconfigured to not be electrically coupled together to form a singleelectrical circuit for the device.

10. The device of any of these embodiments, wherein the stator assemblyconsists of only three stator panels.

11. The device of any of these embodiments, wherein the rotors consistof only two rotors.

12. The device of any of these embodiments, further comprising:

a respective spacer disposed between axially adjacent ones of the statorpanels; and

axial spacers between the stator assembly and the rotors, wherein theaxial spacers set axial air gap spacings between the stator assembly andthe rotors.

13. The device of any of these embodiments, wherein each respective PCBcomprises PCB layers, each coil on a respective stator panel is formedby a single, concentric, electrically-conductive trace on a single PCBlayer of the respective PCB, the coils on each PCB layer arerotationally aligned, with respect to the axis, with the coils on otherones of the PCB layers, and each trace is connected serially or inparallel within the respective PCB to other traces on a same PCB layerand on different PCB layers of the respective PCB.

14. An axial field rotary energy device, comprising: [0450] a housinghaving an axis with an axial direction; [0451] a stator assemblycomprising a plurality of single-phase stator panels that areaxially-stacked and discrete panels from each other, the stators panelsare mechanically and stationarily coupled to the housing, the statorpanels are coupled in a substantially axially abutting relationship,each stator panel comprises a respective printed circuit board (PCB)having respective coils that are electrically conductive andserially-connected within the respective PCB; and

each respective PCB comprises PCB layers, each coil on a respectivestator panel is formed by a single, concentric, electrically-conductivetrace on a single PCB layer of the respective PCB, the coils on each PCBlayer are rotationally aligned, with respect to the axis, with the coilson other ones of the PCB layers, and each trace is connected seriallywithin the respective PCB to other traces on a same PCB layer and ondifferent PCB layers of the respective PCB; and [0453] rotors rotatablymounted within the housing on opposite axial ends of the statorassembly, the rotors are mechanically coupled together with a rotorspacer, each rotor comprises magnets, and no rotor is disposed betweenaxially adjacent ones of the stator panels.

15. The device of any of these embodiments, wherein the stator panelsare mechanically coupled directly to each other in an axially abuttingrelationship.

16. The device of any of these embodiments, wherein the stator panelsare rotationally aligned at a single angle with respect to the axis,such that the stator panels are electrically coupled together to form asingle electrical circuit for the device.

17. The device of any of these embodiments, wherein no axial spacer isdisposed between axially adjacent ones of the stator panels.

18. The device of any of these embodiments, wherein the coils extend ina generally radial direction with respect to the axis, each coilcomprises edges that extend in the radial direction, and the coil edgesare substantially parallel to each other.

19. The device of any of these embodiments, wherein the stator assemblycomprises a plurality of electrical phases, the stator panels arerotationally offset from each other, relative to the axis, at a desiredangle, and the stator panels are configured to not be electricallycoupled together to form a single electrical circuit for the device.

20. The device of any of these embodiments, wherein the stator assemblyconsists of only three stator panels, the rotors consist of only tworotors; and the device further comprises:

a respective spacer disposed between axially adjacent ones of the statorpanels; and

axial spacers between the stator assembly and the rotors, wherein theaxial spacers set axial air gap spacings between the stator assembly andthe rotors.

This written description uses examples to disclose the embodiments,including the best mode, and also to enable those of ordinary skill inthe art to make and use the invention. The patentable scope is definedby the claims, and can include other examples that occur to thoseskilled in the art. Such other examples are intended to be within thescope of the claims if they have structural elements that do not differfrom the literal language of the claims, or if they include equivalentstructural elements with insubstantial differences from the literallanguages of the claims.

Note that not all of the activities described above in the generaldescription or the examples are required, that a portion of a specificactivity may not be required, and that one or more further activitiescan be performed in addition to those described. Still further, theorder in which activities are listed are not necessarily the order inwhich they are performed.

In the foregoing specification, the concepts have been described withreference to specific embodiments. However, one of ordinary skill in theart appreciates that various modifications and changes can be madewithout departing from the scope of the invention as set forth in theclaims below. Accordingly, the specification and figures are to beregarded in an Illustrative rather than a restrictive sense, and allsuch modifications are intended to be included within the scope ofinvention.

It can be advantageous to set forth definitions of certain words andphrases used throughout this patent document. The term “communicate,” aswell as derivatives thereof, encompasses both direct and indirectcommunication. The terms “include” and “comprise,” as well asderivatives thereof, mean inclusion without limitation. The term “or” isinclusive, meaning and/or. The phrase “associated with,” as well asderivatives thereof, can mean to include, be included within,interconnect with, contain, be contained within, connect to or with,couple to or with, be communicable with, cooperate with, interleave,juxtapose, be proximate to, be bound to or with, have, have a propertyof, have a relationship to or with, or the like. The phrase “at leastone of,” when used with a list of items, means that differentcombinations of one or more of the listed items can be used, and onlyone item in the list can be needed. For example, “at least one of: A, B,and C” Includes any of the following combinations: A, B, C, A and B, Aand C, B and C, and A and B and C.

Also, the use of “a” or “an” are employed to describe elements andcomponents described herein. This is done merely for convenience and togive a general sense of the scope of the invention. This descriptionshould be read to include one or at least one and the singular alsoincludes the plural unless it is obvious that it is meant otherwise.

A printed circuit board (PCB) is also known as a printed wiring board(PWB), since such a board, as manufactured, usually contains wiring onone or more layers, but no actual circuit elements. Such circuitelements are subsequently attached to such a board. As used herein, nodistinction between PCB and PWB is intended. As used herein, a coil on aPCB is an electrically conductive coil. As used herein, a component orobject “integrated with” a structure can be disposed on or within thestructure. Such a component or object can be mounted, attached to, oradded to the structure after the structure itself is manufactured, orthe component or object can be embedded within or fabricated with thestructure.

Some embodiments described herein utilize one via to couple together twocoils. In other embodiments a plurality of vias can be provided insteadof a single via to couple together such coils.

The description in the present application should not be read asimplying that any particular element, step, or function is an essentialor critical element that must be included in the claim scope. The scopeof patented subject matter is defined only by the allowed claims.Moreover, none of the claims invokes 35 U.S.C . . . sctn. 112(f) withrespect to any of the appended claims or claim elements unless the exactwords “means for” or “step for” are explicitly used in the particularclaim, followed by a participle phrase identifying a function. Use ofterms such as (but not limited to) “mechanism,” “module,” “device,”“unit,” “component,” “element,” “member,” “apparatus,” “machine,”“system,” “processor,” or “controller” within a claim is understood andintended to refer to structures known to those skilled in the relevantart, as further modified or enhanced by the features of the claimsthemselves, and is not intended to invoke 35 U.S.C . . . sctn. 112(f).

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that cancause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

After reading the specification, skilled artisans will appreciate thatcertain features are, for clarity, described herein in the context ofseparate embodiments, can also be provided in combination in a singleembodiment. Conversely, various features that are, for brevity,described in the context of a single embodiment, can also be providedseparately or in any subcombination. Further, references to valuesstated in ranges include each and every value within that range.

We claim:
 1. An axial field rotary energy device, comprising: a housinghaving an axis with an axial direction, a rotor with a magnet, a statorcomprising a printed circuit board (PCB) having a plurality of coilsthat are electrically conductive and interconnected so that anelectrical current that flows through the plurality of coils causes thedevice to operate; a control circuit comprising a power converter and avariable frequency drive; a housing sensor integrated within thehousing, wherein the housing sensor is configured to monitor, detect orgenerate data regarding operation of the device and is hard-wired orwirelessly connected to the control circuit; and a stator sensorintegrated with the PCB, wherein the stator sensor is configured tomonitor, detect or generate data regarding operation of the device andis hard-wired or wirelessly connected to the control circuit.
 2. Thedevice of claim 1, wherein the device comprises a motor, and the powerconverter is configured to convert an external AC voltage to an internalAC voltage having a different magnitude and frequency than the externalAC voltage.
 3. The device of claim 1, wherein the device comprises amotor, and the power converter is configured to convert an external DCvoltage to an internal AC voltage, wherein the internal AC voltage isconfigured to be provided to the stator to drive the device.
 4. Thedevice of claim 1, wherein the device comprises a generator, and thepower converter is configured to convert an internal AC voltagedeveloped in the stator to an external AC voltage.
 5. The device ofclaim 1, wherein the device comprises a generator, and the powerconverter is configured to convert an internal AC voltage developed inthe stator to an external DC voltage.
 6. The device of claim 1, whereinthe control circuit is integrated inside the housing with the rotor andstator.
 7. The device of claim 1, wherein the control circuit is locatedremotely away from and outside of the housing.
 8. The device of claim 1,wherein the operational data comprises at least one of power,temperature, rate of rotation, rotor position, or vibration data.
 9. Thedevice of claim 1, wherein the housing sensor comprises at least one ofa Hall effect sensor, encoder, optical sensor, thermocouple,accelerometer, gyroscope or vibration sensor.
 10. The device of claim 1,wherein the operational data comprises at least one of power,temperature, rate of rotation, rotor position, or vibration data. 11.The device of claim 1, wherein the housing sensor comprises at least oneof a Hall effect sensor, encoder, optical sensor, thermocouple,accelerometer, gyroscope or vibration sensor.
 12. The device of claim 1,wherein the stator sensor is configured to be powered by and connectedto the coil through a separate electrical connection that is disposed onor within the PCB.
 13. The device of claim 1, further comprising asecondary coil integrated with the PCB that is coupled to the statorsensor, wherein the secondary coil is configured to utilize magneticflux developed during operation to provide power for the stator sensor.14. The device of claim 1, wherein the stator comprises PCB layers, thestator is configured to comprise a plurality of electrical phases, anddifferent ones of the electrical phases are on different PCB layers. 15.The device of claim 1, wherein the stator comprises a plurality ofdiscrete PCB stator segments that are mechanically and electricallycoupled together.
 16. The device of claim 15, wherein the statorsegments comprise PCB layers, and each segment comprises a plurality ofelectrical phases, and different ones of the electrical phases are ondifferent PCB layers.
 17. The device of claim 15, wherein each statorsegment comprises at least one circuit on one of the outer layers of thePCB segment.
 18. The device of claim 17, further comprising a connectorwire extending between two of the circuits to electrically connect therespective segments.
 19. The device of claim 18, wherein each circuitconnected by the connector wire connects to one of the coils on a layerof the respective stator segment.
 20. The device of claim 19, whereinthe stator segments have mounting pads on the outer edge that are joinedby clasps.
 21. The device of claim 20, wherein the clasps are secured bysets of nuts and bolts.
 22. The device of claim 20, wherein each of theclasps comprise an alignment tab that can be positioned into a side wallslot of the axial field rotary energy device housing.
 23. The device ofclaim 20, wherein mounting pads of the stator segments are made of anelectric conductive material and are electrically connected through theclasps, wherein the clasps comprise conductive material on innersurfaces thereof.
 24. The device of claim 23, wherein the mounting padis discontinuous and separated into at least two pieces, with each piececoupled to respective terminals of the coils of the stator segments, andthe stator segments are serially connected via the clasps.
 25. Thedevice of claim 19, wherein inner diameter edges of the stator segmentsslide into a rotor spacer comprising an annular ring with a channel. 26.An axial field rotary energy device, comprising: a housing having anaxis with an axial direction, a rotor with a magnet, a stator comprisinga printed circuit board (PCB) having a plurality of coils that areelectrically conductive and interconnected so that an electrical currentthat flows through the plurality of coils causes the device to operate,the stator also having a stator sensor integrated with the PCB; whereinthe stator comprises a plurality of discrete PCB stator segments thatare mechanically and electrically coupled together in a co-planararrangement, each of stator segments comprise PCB layers, and eachsegment comprises a plurality of electrical phases, and different onesof the electrical phases are on different PCB layers; and a controlcircuit comprising a power converter and a variable frequency drive. 27.The device of claim 26, further comprising a secondary coil integratedwith the PCB that is coupled to the stator sensor, wherein the secondarycoil is configured to utilize magnetic flux developed during operationto provide power for the stator sensor.